Welding Consumable Handling Storage & Issue Control Procedure

Contract : 4500010835
Document Number
WELDING CONSUMABLE HANDLING STORAGE & ID-BKP-SOME-2009-509028

ISSUE CONTROL PROCEDURE
Revision: 0.1 Status : IFC
Document Type : PRC System/Subsystem : N/A Discipline: QUA Date : 07 – 08 - 2021

Originator Document No : N/A Page 1 of 19
PT PERTAMINA HULU MAHAKAM

BEKAPAI 3
SURFACE FACILITIES MODIFICATION AND
DOGLEG INSTALLATION (EPCIC)
WELDING CONSUMABLE HANDLING STORAGE

& ISSUE CONTROL PROCEDURE
CLASS : 1
0.1 07-Aug-2021 IFC Issued for Comment WHY IP / AU SG
Rev Date Status Revision memo Issued Checked Approved COMPANY
This document is the property of Pertamina Hulu Mahakam and shall not be disclosed to third parties or reproduced without permission
of the COMPANY. Electronic Filename: ID-BKP-SOME-2009-509028_rev0.1.pdf
Contract : 4500010835
Document Number


TABULATION OF REVIEW PAGES
REVISION REVISION
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Contract : 4500010835
Document Number


COMMENT TABULATION
No PHM COMMENT CONTRACTOR RESPONSE
Contract : 4500010835
Document Number


TABLE OF CONTENTS
1. INTRODUCTION............................................................................................................................. 5
1.1 Plant Description ................................................................................................................... 5
1.2 Project General Description and Purpose .......................................................................... 5
2. DOCUMENT SCOPE ...................................................................................................................... 7
3. REFERENCE DOCUMENT ............................................................................................................ 7
3.1 Company Specification......................................................................................................... 7
3.2 International Code and Standard ......................................................................................... 7
3.3 COMPANY Supplied Document ........................................................................................... 7
3.4 Project Document.................................................................................................................. 7
4. ABBREVIATIONS AND DIFINITIONS ........................................................................................... 8
5. RESPONSIBILITIES ....................................................................................................................... 8
6. HANDLING, STORAGE & RELEASE WELDING CONSUMABLE .............................................. 9
6.1 General .................................................................................................................................. 9
6.2 Exotic Consumable Handling .............................................................................................. 9
6.3 Manual Metal Arc Welding Electrodes (SMAW Electrodes) ............................................. 9
6.4 TIG Consumables ............................................................................................................... 10
6.5 Quiver control Handling .................................................................................................... 10
7. REQUEST & RELEASE ELECTRODES...................................................................................... 10
8. WELDING CONTROL MONITORING & QUALITY AUDITS ....................................................... 11
9. APPENDICES ............................................................................................................................... 11
Appendix 1 : Weld Consumable Request / Issue Requisition Form .................................... 12
Appendix 2 : Weld Consumable Issuance Form ................................................................... 13
Appendix 3 : Low Hydrogen Welding Electrodes Oven Control Register form ................. 14
Appendix 4 : Flowchart for Electrode Drying & Baking ........................................................ 15
Appendix 5 : Quiver Control Register Form .......................................................................... 16
Appendix 6 : Validation Inspection Reports .......................................................................... 17
Appendix 7 : QC Passed Stickers ........................................................................................... 18
Appendix 8 : Incoming and Outgoing Consumable record .................................................. 19
Contract : 4500010835
Document Number


1. INTRODUCTION
1.1 Plant Description
Bekapai is a COMPANY’s oil field located at offshore area in the Mahakam delta (East
Kalimantan) with water depths 30 – 40 meters and located about 40 kilometers south east of
the Senipah terminal.
COMPANY continues to develop of mature Bekapai offshore oil filed which was discovered in
1972 and start to production in 1974, with current facilities are:
 Nine (9) satellite wellhead platforms & inter-platform pipelines;
 Production (BP) & LQ platforms;
 12” export pipeline to Senipah Terminal (BP1-SNP);
 12” export pipeline to Peciko field SWP-K (BA-SWPK).
All effluents from satellite platforms are transported to BP1 and BA in order to have gas-oil-
water processing unit (separation, pumping, compression, and oily water treatment).
Production fluid from Bekapai field is routed to two (2) locations; multiphase production (mostly
gas and oil) is exported to Senipah Terminal (TPA) via 12” BP1-SNP pipeline and gas
production is exported to Peciko Field via 12” BA-SWPK Pipeline. The network of BEKAPAI
Platforms is shown in figure below.
1.2 Project General Description and Purpose

General Description
Bekapai development phase 3 covers modifcation of existing production facilities in order to
accommodate drilling program of several new wells with potential oil and gas reserve from
Bekapai filed. Modification and intervention of the existing offshore production facilities are for:
 BE and BH as the main platforms;
 BG and BA as host platforms;
 Reutilization of existing 6” inter-platform pipelines between BH to BG and BE to BA.
Contract : 4500010835
Document Number


With the current conditions:

 BH and BE as satellite wellhead platform, located at eastern of Bekapai field, with
minimum production and safety system without pressure relief system, where each
platform is hosting three (3) wells:
- One (1) BH well is still in production
- All BE wells are not in production
 BG is still in operating, latest development phase 2B was completed in 2015 with
additional production wells
 BA is a hub platform, gas export point to Peciko SWP-K without any wells in production
 6” pipeline from platform BE to BA are being preserved. The exsiting pipeline is not
equipped with dogleg
 6” pipeline from platform BH to BG is still in operating
In general, the new equipment under Bekapai 3 is illustrated below:
BE & BH Platform
Project Purpose
 Increase oil and gas reserves recovery by Reserve: 22.1 BcfGas & 2.8 MbblOil +
Condensate
 Drilling of 5 new wells from existing BE & BH platforms, with :
- Modification of the existing BE & BH
- Reuse of existing 6" pipeline from BE to BG (3.6 km) & 6" pipeline from BH to BG (1.9 km)
- Modification and integration work at the BA, BG & BP platforms
-
Contract : 4500010835
Document Number


2. DOCUMENT SCOPE
Purpose of this document is to describe the required Welding consumable handling storage &
issue Control procedure work to deliver the Bekapai 3 Surface Facilities Modification and
Dogleg Installation (EPCIC) project. This is required in order to prove that the work is
carried out properly accordingly to the applicable Code / Specification.
3. REFERENCE DOCUMENT
3.1 Company Specification
No Document Number Document Title

1 MHK-COMP-SPE-EP-PVV-0171 Rev. 0 Steel piping fabrication
Welding of pressure containing piping
2 MHK-COMP-SPE-EP-PVV-0611 Rev. 0
and equipment
Specification – Fabrication of Offshore
3 MHK-COMP-SPE-EP-STR-0301 Rev. 0
Steel Structure
Specification – Material of Offshore Steel
4 MHK-COMP-SPE-EP-STR-0201 Rev. 0
Structure
3.2 International Code and Standard

Specifications for welding rods, electrodes,
1 ASME Section II C Rev. 2017
and filler metals.
3.3 COMPANY Supplied Document

1 Exhibit A Scope of Work
2 Exhibit C Work Time Schedule
3.4 Project Document
1 ID-BKP-SOME-2009-503001 Project Execution Plan
2 ID-BKP-SOME-2009-501020 Project Quality Plan
Contract : 4500010835
Document Number


4. ABBREVIATIONS AND DIFINITIONS

ASME : American Society of Mechanical Engineering
PQR : Performance Qualification Record
WPS : Welding Procedure Specification
AWS : American Welding Society
TIG : Tungsten Inert Gas
SMAW : Shield Metal Arc Welding
5. RESPONSIBILITIES
5.2 Store man

The Store man is responsible for issuing welding consumables (electrodes, wire and flux) to
the welder and welding operator. The Store man is also responsible for scrapping damaged
consumables. Items which are found nonconforming to the specifications shall be quarantined
and Store man shall inform any discrepancies to QC Inspector.
5.3 Welding Supervisor
The welding supervisor / foreman shall make request of electrodes, rod, wire or flux before
welding start, to the store man. Welding supervisor / foreman shall filled the welding
consumable requisition form completely with min. quantity required, consumable type, AWS
no. or brand name (based on concern WPS), diameter and location of work. The request shall
be signed by welding Inspector (QC) to checked the compliance against WPS. After receiving
the requisition sign by welding foreman, the store man will issue the requested electrode, rod,
and wire or flux the welder or welding operator. The store man shall filled the welding
consumable issuance form with min. quantity issued, consumable type, AWS no. or brand
name, diameter, batch no, location of work and receiver name.
5.3 Warehouse Supervisor
The warehouse Supervisor is responsible for withdrawal of consumables from warehouse. He
is also responsible for storage and returned of welding consumables.
5.4 Welding Engineer
The Welding Engineer is responsible for inspection and issuance of inspection report,
traceability of identification electrodes confirms with certificate and also codes and client’s
specifications.
5.5 QC inspector
QC Inspector shall be responsible for the inspection of incoming welding consumables and
control of the low hydrogen electrodes when baking and holding is required.
5.6 Welder
The individual welders are responsible for ensuring that while production, welding electrodes
are in their custody, from receipt from store man, during welding operations, to the return of
any unused welding electrodes to the store. Each welder shall be provided with proper
portable heated quiver during production to protect low hydrogen electrodes from humidity.
Contract : 4500010835
Document Number


6. HANDLING, STORAGE & RELEASE WELDING CONSUMABLE

6.1 General
 Storage facilities will be equipped with Holding oven, Baking Oven, Quiver, Thermometer
(room temperature), Temperature gun, AC (Air Conditioner)
 All consumable, low – hydrogen shall be stored in accordance with the Manufacturer’s
Current recommendations.
 consumable for Carbon Steel & Stainless Steel including duplex shall be segregate on
storage also oven & quiver.
 All consumable shall be stored in their original sealed container packing
 Low hydrogen electrodes that have been in direct contact with water shall be definitely
rejected and remove from site.
 Welding consumable certificates requirements shall conform to EN 10204 with type mill-
test certificates, which shows test result actually obtained for chemical and mechanical
properties of the said batches. (refer to specification MHK-COMP-SPE-EP-PVV-611
Rev.1 Table 3 - Certificate Requirement)
6.2 Exotic Consumable Handling
Welding consumables shall be stored with care on a specific separate area, under dry
conditions in their original unopened packing. After opening of containers, storage and
handling of electrodes, fluxes and other welding materials shall be as specified in the
Manufacturer's recommendations. Electrode, filler wire or flux that are damaged, damp,
greasy or oxidised must not be used. Low hydrogen electrodes should be vacuum packed.
Welding electrodes shall be stored in calibrated ovens at the temperature between 120°C and
150°C. When issued for production they are placed in heated quivers capable of maintaining a
minimum temperature of 70°C. Flux shall be stored in calibrated ovens at the temperature
between 120°C and 150°C after opening of the packing. All welding consumable which have
been in direct contact with water shall be definitively rejected.
6.3 Manual Metal Arc Welding Electrodes (SMAW Electrodes)

Low - Hydrogen Electrodes (Basic Electrodes) is kind of manual metal arc welding electrodes
which is used for this subject.
 Low hydrogen electrodes with vacuum packaging shall be stored in holding oven at
temperature 150°C for at least 1 hour, and placed in heated quiver by each welder for
production as per requisition immediately after removal from hermetically sealed
containers.
 Each oven used for holding or re-baking, shall have a calibrated thermometer.
 All baking / drying activities and holding details shall be recorded on Low Hydrogen
Welding Electrodes Oven Control Register form in Appendix-3.
 Before placing of electrodes in oven, the oven must be switched “ON” to reach the 100°C
minimum, in order to remove any moisture content.
 During welding production, each welder shall ensure that low hydrogen electrodes are
being kept in heated quiver with temperature minimum 70°C. The lids shall be closed at
all times from the time of receipt to the return of unused electrodes to the store.
Contract : 4500010835
Document Number


 Surplus of all unused electrodes, which have been exposed to atmosphere for more or
less than 4 hours shall be marked with white paint (heat resistant paint) and returned to
the store for pre-drying at a temperature of 120°C overnight. Then this electrodes shall be
re-baked at a temperature of 300°C - 350°C for two hour minimum and finally all re-baked
electrodes shall kept in holding oven at temperature 150°C. The quiver used for electrode
storage shall be validated periodically.
 Unused electrodes which are identifiable and undamaged can be accepted back into
storage and subjected to re-bake one time only. If returned after being issued a second
time the electrodes shall be discarded.
 Any remaining electrodes that have been subjected to one baking cycle, issued to site but
have not been used shall be returned to the storage, the stubs coated over the white paint
marking with red paint and then be discarded.
6.4 TIG Consumables
 TIG rod shall be clean, free from grease, damp, dirt, oil and rust.
 TIG rod shall have identification based on AWS Class embossed on both ends or with the
flags. Other method to use color coded painted on both ends. The paint color is based on
the AWS Class. Each manufacturers have already use identification ( print) AWS class
and brand name on both ends.
 The gas used for welding is Welding Grade (WG) or higher grade (High Purity / UHP)
provided with Certificate.
 TIG rod for duplex & austenitic stainless steel shall be cleaned with acetone prior to use.
6.5 Quiver control Handling
All quivers used in welding operations are quivers that have passed Inspections by the
Equiptment Department and are validated by QC inspectors after being validated. QC
inspectors issue validation inspection reports ( See Appendix-6) and provide QC
PASSED Stickers at quivers ( See Appendix-7)
 Quiver shall be checked the temperature per 6 months to control the temperature meet
the minimum requirement temperature in 70°C. When the temperature’s quiver less than
70°C, the quiver shall be replaced with new quiver. Quiver used on the welding operation
is the quiver that passed Inspection by Electrical Departement. Quiver control register
shall be available on welding consumable storage.
 All quivers used in this project will be controlled and recorded in the Quiver control
register ( See Appendix-5)
7. REQUEST & RELEASE ELECTRODES
 Welding consumable shall only be issued by the responsible Store man when a Welding
Consumable Request and Issue Requisition form (see Appendix-1) has been completed
by the welding supervisor / foreman.
 the limit quantity of consumables to be taken will be adjusted according to the needs and
the number of joins to be welded
 The welding supervisor / foreman shall make request of electrode, rod, wire or flux to the
store man before welding started. Welding supervisor / foreman shall filled the welding
Contract : 4500010835
Document Number


consumable requisition form completely with min. quantity required, consumable type,
AWS no., brand name ( based on concerned WPS ), diameter and location of work.
 After receiving a request signed by the welding foreman, store man asks for QC inspector
to verify the consumables, after the QC inspector verify the consumables will be sign the
request and the store man will issued the requested electrode, rod, wire or flux to the
welder or operator welding (see Appendix-2)
 The issuance form from store man shall be detailed the consumable type, AWS no., brand
name, diameter, quantities issued, name of recipient (welder) and location of work.
 It is recommended to limits the quantity to be taken.Bear in mind rather than baking and
using USED electrode. It will be better to use a new one.
8. WELDING CONTROL MONITORING & QUALITY AUDITS

 During the course of the project the QC Department shall monitor the adherence of
welding storage, baking/drying, issue and return activities at each location.
 Quality Audits shall be conducted also to ensure that all the requirements of this
procedure are being observed and followed.
 Audits reports shall be issued recording the result of audits and any Non-Conformances or
Corrective Actions observed during Audits.
 The foreman or welding inspector responsible to daily inspection of electrode before work
and after work to be done. Follow-up shall be initiated to ensure the close out of any Non-
Conformances or Corrective Actions reports issued during the course of audits.
 Store Man Recorded All incoming and outgoing consumables shall be recorded on
specific data log on a daily basis. ( See Appendix-8 )
9. APPENDICES
Appendix 1 : Weld Consumable Request / Issue Requisition Form
Appendix 2 : Weld Consumable Issuance Form
Appendix 3 : Low Hydrogen Welding Electrodes Oven Control Register form
Appendix 4 : Flowchart for Electrode Drying & Baking
Appendix 5 : Quiver Control Register Form
Appendix 6 : Validation Inspection Reports
Appendix 7 : QC Passed Stickers
Appendix 8 : Incoming and Outgoing Consumable record
Contract : 4500010835
Document Number


Appendix 1 : Weld Consumable Request / Issue Requisition Form
Revision Index
WELDING CONSUMABLE HANDLING,
STORAGE & ISSUE CONTROL PROCEDURE Rev Status
0.1 IFC
F & I WELDING REQUISITION FORM ( FIWR)

FIWR. No. : / WH / 2021
FABRICATION
INSTALLATION
DIAMETER
No QUANTITY (Kg) BRAND NAME AWS CLASS BACTH No. / LOT No. REMARKS
(mm)
Note : REQUEST BY, VERIFIED & APPROVAL

WELDING FOREMAN / SUPERVISOR CONSTRUCTIONQC INSPECTOR
Name: Date : Name: Date :
ǦǦ ǦͲͺȀͳͻ
Contract : 4500010835
Document Number


Appendix 2 : Weld Consumable Issuance Form
Revision Index
WELDING CONSUMABLE HANDLING, STORAGE &
ISSUE CONTROL PROCEDURE Rev Status
0.1 IFC
F & I WELDING ISSUANCE FORM (FIWI)

FIWI. No. : / WH / 2021
FABRICATION
INSTALLATION
BRAND AWS DIAMETER ISSUED BY RECEIVED BY

No QUANTITY ( Kg ) BACTH No. / LOT No.
NAME CLASS (mm) (NAME & SIGN) (NAME & SIGN)
Note : WAREHOUSE SUPERVISOR

Sign
Name : Date :
ǦǦ ǦͲͺȀͳͻ
Contract : 4500010835
Document Number


Appendix 3 : Low Hydrogen Welding Electrodes Oven Control Register form
Revision Index
WELDING CONSUMABLE HANDLING, STORAGE & ISSUE
CONTROL PROCEDURE Rev Statu
0.1 IFC
BAKING DRYNG WELDING ELECTRODE - OVEN CONTROL REGISTER FORM ( BDWE )

BDWE. No. : / WH / 2021
REBAKING OVEN HOLDING OVEN

DESCRIPTION UNUSED
DATE DETAILS 300ºC - 350ºC DETAILS Max 150ºC
ELECTRODE REMARKS
(In Oven) SIZE DIA CONDITION Time Time Time Time
Lot.No AWS. NO. QTY BATCH NO. RETURN
(mm) Used/Unused (In) (Out) (In) (Out)
Note : Prepared By Checked By

STOREMAN WAREHOUSE SUVERVISOR
NAME : NAME :
SIGN : DATE : SIGN : DATE :
ǦǦǦͲͺȀͳͻ
Contract : 4500010835
Document Number


Appendix 4 : Flowchart for Electrode Drying & Baking
WELDING CONSUMABLE CONTROL FLOW CHART
CONSTRUCTION
WAREHOUSE STORE TRANSIT STORE/WELDING CONTROL CENTER (PRODUCTION) QC TEAM
SUPERVISOR
PROCUREMENT
RECEIVING
INSPECTION OF WELDING
CONSUMABLES BY STORE
MAN
CHECK
No WAREHOUSE Certified
STORES Material Test
Report
Yes
CHECK QC TRANSIT STORE
CLEARENCE AT TEMP ≥ 20°C
CENTRAL STORE
Max 150°C
EXPOSED
ATMOSPHERE
T ˃ 4 Hours T ≤ 4 Hours
White Paint
Surplus Return
Marked
Pre-Drying
(Over Night)
Backing Oven
Holdig Oven Quiver Heated to
at temperature 300- Monitor
120°C - 150°C at temperature 70°C
350°C Min 2 Hours
EXPOSED
Welding Monitor
ATMOSPHERE
T ≤ 4 Hours T ˃ 4 Hours
Yellow Paint
Red Marked
Marked
Surplus
Scrapped
Return *
Scrapped
Note :
* Maximum Surplus Retrun electrode only 2 times, after that scrapped
** All wet, damaged and damp electrodes shall be rejected.
Contract : 4500010835
Document Number


Appendix 5 : Quiver Control Register Form
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Contract : 4500010835
Document Number


Appendix 6 : Validation Inspection Reports
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Contract : 4500010835
Document Number


Appendix 7 : QC Passed Stickers
Contract : 4500010835
Document Number


Appendix 8 : Incoming and Outgoing Consumable record

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Welding Consumable Handling Storage & Issue Control Procedure

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Welding Consumable Handling Storage & Issue Control Procedure

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Contract : 4500010835

WELDING CONSUMABLE HANDLING STORAGE & ID-BKP-SOME-2009-509028

Document Type : PRC System/Subsystem : N/A Discipline: QUA Date : 07 – 08 - 2021

PT PERTAMINA HULU MAHAKAM