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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
Rev.
Date
Description
Page 1 of 9
S.J.N
Prepared
S.J
G.V.A
Reviewed
Approved
Approved
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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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
3. ABBREVIATIONS
AWS
WPS
PQR
WQT
ASME
:AmericanWeldingSociety
:Weldingprocedurespecification
:Procedurequalificationrecord
:Welderqualificationtest
:AmericansocietyofMechanicalengineers
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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
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.
He shall liaise with Customer and contractor for Quality related matter.
ShallreviewInspectionreports,testcertificates&prepareTQfortechnicalinformation.
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Shallensurethattherequirements&specificationsstipulatedinthismethodstatementare
appliedandmaintainedthroughouttheprojectconstructionperiod
QA/QCEngineer
ShallreporttoQA/QCManager
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.
Shallconducttoolboxtalkpriortostartofwork&ensurecompliancewithWPS
Materialcontroller
ShallreporttoMaterialManager
Shallensurethatallmaterialsarestored&segregatedaspermaterialspecification&size
schedulewise.
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Shallensurethatallboughtoutprojectmaterialsareinspected&certifiedbyconcern
authority.
Shallensurethatallmaterials/spoolsareissuedforinstallationinaccordancewithMIR.
SafetyOfficer
ShallreporttoHSEManager
Ensure valid work permit for all activities performed during installation and permit
conditionarecomplied.
EnsurethatproperPPEsarebeingusedbyemployeesduringwork.
IdentifyspecifichazardsandassistconstructionSupervisiontoensuresafeprogressof
workactivity.
CoordinatewithcontractorsiteHSEstaffforeffectivecontrolofactivityatsite.
6. MANPOWER
SiteManager
ConstructionManager
QA/QCManager
QA/QCEngineer
QCInspector
WeldingSupervisor/Foreman
Welders
Materialcontroller
HSEOfficer
Storekeeper
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7. EQUIPMENT&TOOLS
BakingOven
HoldingOven
WeldingMachines
Argoncylinder
Weldingconsumables
8. SEQUENCEOFACTIVITIES
Consumable Certification.
Equipment Calibration.
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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9.1.3.
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
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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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.
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 .
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9.1.9
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