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DOCUMENT NO : QA/QC-XXX
REVIEWED & APPROVED BY
SIGN 1 REVISED DATE 0 FIRST ISSUE SIGN. DATE
NO.QA/QC-XXX WELDING CONSUMABLE CONTROL PROCEDURE PAGE: 1 OF 7 REV. 0 1 DATE FEBRUARY 2005 SEPTEMBER 2006 PAGE No. DESCRIPTION PROCEDURE COMPLETELY REVISED. 1 REVISION CONTROL SHEET REV.01 REV.0 . THIS SUPERSCEDES PROCEDURE VEW/10.
3 WELDING CONSUMABLES STORAGE TREATMENT OF WELDING CONSUMABLES MAINTENANCE OF BAKING/HOLDING OVENS APPENDICES Appendix 1 Appendix 2 Appendix 3 Appendix 4 MATERIAL ISSUE VOUCHER (MIV) TABLE FOR TREATMENT OF WELDING CONSUMABLES ELECTRODE BAKING / HOLDING OVEN AND FLUX OVEN STATUS DAILY ELECTRODE BAKING LOG .1 6. 2. 5.2 6. SCOPE APPLICATION OBJECTIVES RESPONSIBILITIES DEFINITIONS PROCEDURE 6. 1 INDEX 1. 4. NO. 3.QA/QC-XXX WELDING CONSUMABLE CONTROL PROCEDURE PAGE: 2 OF 7 REV. 6.
OBJECTIVES The objective of this procedure is to ensure that adequate control is being exercised for receipt.0 3. • Ensure that electrodes are properly stacked in the baking ovens. handling.QA/QC-XXX WELDING CONSUMABLE CONTROL PROCEDURE PAGE: 3 OF 7 REV. issue. storage. handling and issuance of welding consumables. • Distributing electrodes to shop once or twice a shift. 2. • Register electrodes / baking details on “Daily electrodes Baking Log ” (Refer appendix 3). • Offer the cnsumable to QA/QC for inspection. APPLICATION This procedure is applicable for Velath Engineering works & Velath Engineering International FZC workshop facilities. sizes.0 SCOPE This procedure describes the minimum requirements to be complied with for receipt. • Store the accepted batches of consumables in the stores. quantities and any visible damage and sign off the delivery note from supplier. • Inspect the incoming welding consumables received with regard to types.0 . of the consumables received tally with those in the batch/lot certificates. reporting on electrodes issue by coordinating with the Production Engineeer. and treatment of welding consumables prior to use in order to ensure acceptable weld quality during fabrication & erection.1.0 4. 1 1. storage. • The damaged consumables will be segregated in the designated quarantine area for return to the supplier. Store Incharge / Store Keeper His duties include the following: • Verify that batch/lot nos. • Store the various consumables in specified location in a clean area in the Store. RESPONSIBILITIES 4. NO. who will specify the types and sizes of electrodes to be issued. • Properly bake the electrodes in baking ovens in accordance with table 1 of this procedure (Refer appendix 2) and transferring the same to holding ovens prior to issue to workshop. • Segregate the collected unused electrodes at the end of each shift and rebaking. if the consignment is accepted.
C.2 5. • Arrange the collection of unused electrodes at the end of each shift and return the same for re-baking. treated and issued in accordance with this procedure. In case any quiver is found not working. size and quantities of consumables to the Welders as required. • Ensure that quivers used by Welders are in good working condition through routine inspection and notify Production Engineer of any discrepancy.4 SMAW Electrodes GTAW Filler Wires SAW Filler Wires SAW Flux Electrodes that are used for Shielded Metal Arc welding process Filler Wires that are used for Gas Tungsten Arc welding process Filler Wires that are used for Submerged Arc welding process Granular flux that are used for submerged Arc welding process 6. Q.QA/QC-XXX WELDING CONSUMABLE CONTROL PROCEDURE PAGE: 4 OF 7 REV.0 PROCEDURE . • Inform the concerned personnel of any discrepancy or deviation from the specified baking cycle and holding temperature. he shall ensure that such quivers are replaced and the electrodes kept in those malfunctioning quivers are returned for re-baking. • Ensure that Welders under his control store the electrodes in heated quivers and that quivers are in good working condition. 1 • Ensure that re-baked electrodes are issued prior to issuing electrodes baked for the first time by storing the re-baked electrodes in separate section in the holding oven.0 DEFINITIONS 5.Engineer is responsible for the following: • Check that welding consumables are stored. 4. NO. • Issue the required electrodes on a first in. 4.C. Engineer: The Q. first out basis to the work shop.1 5. they are returned to the quarantine area for disposal.2.3 5. If any of the re-baked electrodes are unused. • Check the temperature of all baking and holding ovens twice a day and record the same in electrode baking/ holding oven status record (See appendix 2). Production Engineer: Production Engineer is responsible for the following: • Arrange the issuance of the correct type.3 5.
Baked electrodes can be stored in holding ovens for an indefinite period at the specified temperatures.2 Welding Consumables Storage: Welding consumables received in manufacturer's original factory packing.Cellulosic Type: All Cellulosic electrodes from opened containers shall be used directly or stored in heated quivers. but it is good practice to issue electrodes from holding ovens on a first-in first-out basis. electrodes may be stored in baking ovens at specified holding temperature. (See appendix-3). and quantity of electrodes baked. and duration for various types of electrodes based on applicable code/ manufacturer's recommendations are specified in Table 1(See appendix . Treatment of Welding Consumables: 6. strictly as per the cycle recommended by the manufacturer which is specified in table 1 (appendix 2). 1 6. . Consumables shall not be directly exposed to sun or rain.1. The electrodes exposed more than this shall be send for baking. 6. prior to issue. Unused electrodes returned at the end of each shift shall be re-dried in a separate compartment as specified in Table 1. If holding ovens are not available. after inspection.3 SAW Flux: Prior to use all the SAW Fluxes are baked/held at specified temperatures and duration (refer Table 1). All electrodes shall be baked for 2 times only (initial baking and once rebaking) and it shall be ensured that these are consumed. The baking and holding temperature.2.2). The temperature and time specified shall not be exceeded. size. cellulosic electrodes shall be dried in heated ovens. 6. which are issued to the welder and not used.1. shall be scrapped and removed from site. showing type. and held in baking/ holding ovens. Consequently these electrodes shall be held in a separate compartment in holding oven and issued prior to issuing any electrodes baked for the first time. Re-baked Electrodes.2 SMAW Electrodes . batch no. If exposed to humid air for a period exceeding 48 hours. and approval of batch certificates by QC Engineer shall be stored in a clean and covered storage area and handled in such a manner that would prevent any damage or contamination. The Stores Incharge / Stores Keeper shall maintain a daily log.2. NO. time of start and finish of baking for various types of electrodes. SMAW Electrodes Low hydrogen Type: Prior to use.2.QA/QC-XXX WELDING CONSUMABLE CONTROL PROCEDURE PAGE: 5 OF 7 REV. all the welding electrodes except vacuum packed shall be baked in baking ovens at specified temperature and duration. The vacuum packed electrodes can be used directly from its packets and shall be exposed upto a duration as mentioned by the manufacturer. 6.
. prior to redrying of flux. FCAW and SAW Filler Wire Spools/Coils shall be stored in original packing until they are issued to operators for use. GMAW. 6. Unused filler wires shall be returned to stores at the end of the shift. GMAW. Care shall be taken to prevent damage to colour coding/ identification marking on each filler wire. 6. temparature gauge of holding ovens shall be calibrated every year or when there is a discrepancy between the actual temperature and the indicated temperature. Filler Wires: GTAW Filler Wires shall be stored in manufacturer's packing and issued to Welders on a daily basis based on requirement. It shall be ensured that slag particles are removed by sifting. 1 Unused Fluxes at the end of the shift shall be transferred to baking oven for re-drying as per the specified cycle. FCAW & SAW Filler Wires showing signs of rusting shall not be used.QA/QC-XXX WELDING CONSUMABLE CONTROL PROCEDURE PAGE: 6 OF 7 REV. The control thermostat of the baking ovens. NO.4.3 Maintenance of Baking/Holding Ovens A monthly maintenance / check-up shall be conducted by the Maintenance Department electricians to check the condition of the baking/holding ovens.2. Any malfunction detected shall be repaired in situ or at the workshop.
1 120-150°C Indefinite 2 Times 38°-49°C Indefinite 1 Time 250-300°C 2 Hrs.62. E 7018-1. OF TIME FOR BAKING (Note 1) REMARKS 300-350°C 2 Hrs. 120-150°C Indefinite 2 Times 260-280°C or 300-320°C 93-110°C (Note 2) 2 Hrs.S. Electrode E 8016G E 8018-B2 E 8018-C1. E 308L-16. E 7010G E 8010G SAW FLUXES OK 10. 120-150°C Indefinite 3 Times Notes: 1.TABLE . Hr.150°C Indefinite 2 Times 370-420°C 1-2 Hrs. No. No initial baking required. E 309-16 E 309 MOL-16 Ni alloy electrode E NiCr Mo-3 E NiCu 7 Cellulosic Electrodes (LINCOLN) E 6010.71 SAW FLUXES 200-300°C 2 Hrs. TIME TEMP. 120-150°C Indefinite 2 Times TEMP. Inclusive of initial baking. . 120 . 10 to 20 Min.C2. E7018. E 316L-16 E 347-16. 120-150°C Indefinite 2 Times 250-300°C 2 Hrs.C3 E 9018 .M E 11018 – M Stainless Steel Electrode. 2. HOLDING TIME MAX.A. OK 10.1 TREATMENT OF WELDING CONSUMABLES BAKING / REDRYING CONSUMABLE TYPE Carbon Steel Low Hydrogen Electrodes E7016-1. E 7028 L.