Reliance

Procedure For
Re-Order Level Maintenance of
Welding Consumables
(Fast Moving Items)

EPCMD-2-QM00-JEP-ME-034

00

09.04.2013

Issued for
Implementation

TD

KSS

SNS

Rev

Date

Revision

Prepared By

Checked By

Approved By

Reliance
Contents
1.

Purpose ..3

2.

Scope ....3

3.

Reference ...3

4.

Abbreviations and Terms .3

5.

Responsibilities

6.

Methodology

.4

7.

Attachments

.7

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 2 of 15

Reliance
1.

Purpose
The purpose of this work instruction is to give a clear cut guideline for keeping the
minimum required re-order level for fast moving welding consumables for piping,
structural and modification work of equipment. The fast moving welding consumables
are those which are used for day to day construction activities. Accordingly, five
welding consumables are identified as fast moving items under the following AWS
classifications:

2.

E6010 electrodes used for root pass welding of piping in SMAW process.

E6013 electrode used for structural welding in SMAW process.

ER70S-2 filler wire used for root and subsequent passes in piping welding in GTAW
process.

E7018 electrode used for piping as well as structural welding in SMAW process.

EWTh-2 (2% Thoriated Tungsten electrode) used for piping welding in GTAW
process.

Scope
The scope of this procedure is only applicable for the fast moving welding consumables
where stock level is to be maintained at CMC. This scope is limited to the structural,
piping construction activities and equipment modification work carried out by Reliance
for FCO jobs at site as well as internal/external jobs carried out at Fabrication division,
MPC & O & M Group at RIL (Refinery Division), Jamnagar.

3.

Reference
Refer attachments for details.

4.

Abbreviations and Terms

AWS

American Welding Society

CM

Construction Manager

CMC

Construction Material Centre

Contractor

Sub contractor of Reliance

EA

Each (Numbers)

FCO

Field Change Order

FMR

Field Material Requisition

GTAW

Gas Tungsten Arc Welding

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 3 of 15

Reliance

HOD

Head of Department

MPC

Minor Project Cell

O&M

Operation & Maintenance

PFS

Pipe Fabrication Shop (RIL-Jamnagar)

QMD

Reliance Quality Management Department

RIL

Reliance Industries Limited

SFS

Structural Fabrication Shop

SMAW

Shielded Metal Arc Welding

TIG Welding

Tungsten Inert Gas (Arc) Welding

WTG

Welding Technology Group under QMD

Welding consumable

Welding consumable specified here are limited to

welding electrodes, filler wires used in GTAW and SMAW process only.

5.

Responsibilities

CMC store - Managers/Engineer in Charges is responsible for implementing this

procedure in their area.

HOD, QMD is responsible for maintaining this procedure.

DCC is the custodian of this procedure.

6.

Methodology

6.1

Assumptions and considerations:

6.1.1 Welding productivity per day for PFS is considered as 600 to 800 Inch dia. For FCO jobs
at site (executed by Reliance, where consumable supply is under scope of Reliance),
per day the welding productivity is considered as 1000 Inch dia. For MPC and O & M
Group together, the welding productivity per day is considered as 500 Inch dia. Hence
the total welding productivity per day is 2300 Inch dia.
6.1.2 E6013, E7018, ER70S-2 are commonly procured from Indian vendors. E6010 and
EWTh-2 are normally procured as imported items. For procurement of welding
consumables from Indian vendors, the lead time is considered as 45 days and for
imported items, the same is considered as 75 days. So, stock level is to be maintained
accordingly.

6.2

Based on the above inputs, welding consumable consumption is studied and analyzed
through calculations in six different ways as summarized in Annexure-1, 2, 3, 4, 5, 6.

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 4 of 15

Reliance
6.3

6.4

Comparison of Annexure-1, 2, 3, 4, 5, 6
AWS class / Size

Annex-1

Annex-2

Annex-3

Annex-4

Annex-5

Annex-6

E7018/2.5mm

3420Kg

2608Kg

1094Kg

1172Kg

6500

E7018/3.15mm

6480Kg

6085Kg

1953Kg

1586Kg

12000

E7018/4.0mm

1140Kg

870Kg

2031Kg

310Kg

2000

ER70S-2/2.4mm

3750Kg

1270Kg

92Kg

230Kg

3500

ER70S-2/3.15mm

1785Kg

635Kg

Nil

Nil

500

E6010/2.5mm

4312Kg

1275Kg

340Kg

80Kg

4500

E6010/3.15mm

4312Kg

1275Kg

390Kg

4500

E6013/2.5mm

1500Kg

1500Kg

353Kg

810Kg

5000

E6013/3.15mm

3000Kg

3000Kg

703Kg

770Kg

6500

E6013/4mm

500Kg

500Kg

156Kg

140Kg

2000

EWTh-2/2.4mm

3105EA

1700EA

220EA

400EA

3000

EWTh-2/3mm

345EA

200EA

Conclusion :
The data collected over QYI-1 project peak period consumption, average consumption
trend as well as practical data obtained from stores. The matter is discussed thoroughly
to arrive at an optimized figure which will be treated as minimum re-order level.
However depending on quantum of work, the quantity may further increase from time
to time.
Accordingly it is decided to keep the following minimum re-order quantity:

6.5

E7018

2.5mm

2500Kg

E7018

3.15mm

4000Kg

E7018

4.0mm

1500Kg

ER70S-2 2.4mm

2500Kg

ER70S-2 3.15mm

500Kg

E6010

2.5mm

3000Kg

E6010

3.15mm

3000Kg

E6013

2.5mm

2500Kg

E6013

3.15mm

3500Kg

EWTh

2 / 2.4mm

2500EA

As and when the free stock of any item reaches below the specified re-order level, CMC
shall inform QMD. FMR shall be raised to replenish the stock level.

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 5 of 15

Reliance
7.

Attachments

ANNEXURE 1: Estimation of E6010, E7018, ER70S-2, E6010 and EWTh-2 welding

consumables based on data collected from PFS Welding engineering /Reliance field
QMD

ANNEXURE 2: Estimation of E6013 welding consumables based on structural

tonnage data collected from SFS planning

ANNEXURE 3: Estimation of E6013, E6010, E7018, ER70S-2 and EWTh-2 based on

Procedure for Reconciliation of Welding Consumable (EPCMD-2-QM00-JEP-ME-029)

ANNEXURE 4: Estimation of E6013, E6010, E7018, ER70S-2 and EWTh-2 based on

welding consumable issuance data collected from CMC stores for April 2000-March
2001

ANNEXURE 5: Estimation of E6013, E6010, E7018, ER70S-2 and EWTh-2 based on

welding consumable issuance data collected from CMC stores for April 2001-May
2001

ANNEXURE 6 : Minimum stock level maintained during QYI-1 project

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 6 of 15

Reliance
Annexure-1
Estimation of E6010, E7018, ER70S-2, E6010 & EWTh-2 welding
consumable based on data collected from PFS welding engineering/
field QMD
Assumptions and considerations:

Average pipe wall thickness 9.53mm

In PFS, the welding productivity is 600-800dia./day

(Considering only one PFS is functioning for welding activities).

For FCO job executed by Reliance (where welding consumable is under the scope of
Reliance) at site, the welding productivity is 1000 dia/day

For FCO/maintenance job executed by MPC/O&M team (where consumable supply is under
scope of Reliance) at site, the welding productivity is 500 dia./day

1Kg of E7018 electrode is consumed for 8-10 dia welding.

For 10000 dia welding, ER70S-2 consumption is 250-500Kg (wherever there is full
TIG/GTAW e.g. for small bores, the consumption goes up to as high as 500kg. Wherever
GTAW+SMAW combination is used, the consumption is as low as 250Kg).

For 10000 dia welding, E6010 electrode consumption is 500 Kg.

1 EA of EWTh-2 (2.4mm x 150mm length) is consumed for 50 dia welding.

As E7018 and ER70S-2 items are generally procured from Indian vendors, the lead time
for procurement of is 45 days.

As E6010 and EWTh-2 items are generally procured from foreign vendors, the lead time for
procurement is 75 days.

1) E7018 electrode
a) PFS requirement:
Considering 800 dia production welding per day at PFS, E7018 electrode consumption is 80Kg
per day.
Assuming 10% repair, electrode requirement is 88Kg per day.
For 45 days, the requirement is 3960Kg of E7018 welding electrode.
b) Site requirement for FCO jobs (executed by Reliance) :
Considering 1000 dia welding/day, E7018 electrode consumption is 100kg/day
Assuming 10% repair, electrode requirement is 110kg/day.
So for 45 days, the requirement is 4950kg.
c) Site requirement (jobs executed by MPC & O&M Group together):
Considering 500 dia welding/day, E7018 electrode consumption is 50Kg/day
Assuming 10% repair, electrode requirement is 55kg/day.
So for 45days, the requirement is 2475kg
Adding (a)+(b)+(c), the cumulative fig. becomes 11400kg (approx)
This is split in to 30:60:10 ratio for 2.5mm, 3.15mm and 4.0mm dia electrode as follows :

2.5mm

3420Kg

3.15mm

6480Kg

4.0mm

1140Kg

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 7 of 15

Reliance
2) ER70S-2 GTAW (TIG) filler wire
a) PFS requirement:
For 10,000 dia production welding, GTAW filler wire requirement: 250-500Kgs
Considering 800 dia production welding/day, GTAW filler wire requirement is 20-40kg/day
Assuming 10% repair, electrode requirement is 22-44Kg/day
So, for 45 days, the requirement is 990-1980Kg
b) Site requirement for FCO jobs (executed by Reliance):
For 10,000 dia production welding, GTAW filler wire requirement: 250-500Kg
Considering 1000 dia production welding/day, GTAW filler wire requirement is 25-50Kg/day.
So, for 45 days, the requirement is 1125-2250Kg
c) Site requirement (jobs executed by MPC & O&M Group together):
For 10,000 dia production, GTAW filler wire requirement: 250-500Kg
Considering 500 dia production welding/day, GTAW filler wire requirement is 12.5-25Kg/day
For 45days, the requirement is 563-1125Kg
Adding (a)+(b)+(c), the cumulative fig. becomes 2678-5355Kg
Keeping 2:1 ratio for 2.5mm & 3.15mm filler wire, the requirement is:

2.5mm

3750Kg

3.15mm

1785Kg

3) E6010 electrode
a) PFS requirement:
Considering 800 dia production welding/day, electrode requirement is 40Kg/day
For 75days, the requirement is 3000Kg.
b) Site requirement for FCO jobs (executed by Reliance):
Considering 1000 dia production welding/day, electrode requirement is 50Kg/day.
For 75 days, the requirement is 3750Kg.
c) Site requirement (jobs executed by MPC & O&M Group together):
Considering 500 dia production welding/day, electrode requirement is 25Kg/day.
For 75 days, the requirement is 1875Kg
Adding (a)+(b)+(c), the cumulative fig. becomes 8625Kg
Keeping 1:1 ratio, for 2.5mm & 3.15mm electrodes, the requirement is

2.5mm

4312Kg

3.15mm

4312Kg

4) Tungsten Electrode (EWTh-2)

a) PFS requirement:
Considering 800 dia production welding/day, the consumption is 16 EA of Tungsten electrodes
/Day.
For 75 days, the requirement is 1200EA.
b) Site requirement for FCO jobs (executed by Reliance):
Considering 1000 dia production welding/day, the consumption is 20EA/day.
For 75 days, the requirement is 1500EA.

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 8 of 15

Reliance
c) Site requirement (jobs executed by MPC & O&M Group together):
Considering 500 dia production welding /day, the consumption is 10EA/day.
For 75 days, the requirement is 750EA.
Adding (a)+(b)+(c), the cumulative fig. becomes 3450EA
Keeping 90:10 ratio, for 2.4mm & 3.15mm electrodes, the requirement is

2.4mm

3105EA

3.15mm

345EA

Accordingly the total stock level shall be as follows:

AWS Class

Dia (mm)

Matcode

Quantity

E7018

2.5

AWE70182.5

3420Kg

E7018

3.15

AWE70183.15

6480Kg

E7018

4.0

AWE70184

1140Kg

ER70S-2

2.4

AWER70S22.4

3750Kg

ER70S-2

3.15

AWER70S23

1785Kg

E6010

2.5

AWE60102.5

4312Kg

E6010

3.15

AWE60103.15

4312Kg

EWTh-2

2.4

AWEWTH22.4

3105EA

EWTh-2

3.15

AWEWTH23

345EA

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 9 of 15

Reliance
Annexure- 2
Estimation of E6013 welding electrode based on structural tonnage
data collected from SFS planning
Assumptions and Considerations:

In SFS, welding consumable supply was mostly under the scope of contractor for the last
year. However, the minimum requirement of 45 days inventory is required to be kept as
stock item for E6103 electrode considering job emergency.

For last financial year, the quantum of structural fabrication at SFS was approx. 3500Ton

Considering welding consumable requirement as 0.75%wt of total structural fabrication

(Procedure for Reconciliation of Welding Consumable: 200JEPME029) the estimated
welding consumable is 3500Ton x 0.75 x 0.01 i.e 26.25Ton.
So for 1.5months, the requirement is 26.25Ton x 1/12 x 1.5 i.e. 3.3Ton

Assuming 75% of the structure is light structure welded with E6013 electrode. Balance
25% was heavy structure (mostly Desalter structure job) which was welded mostly by
SAW process & a small fraction of heavy structures welded in SMAW process using E7018
electrode which is taken into consideration for calculation.

So, E6013 electrode requirement for SFS for 45 days is 2500Kg (approx).
As per Reconciliation procedure, for the structural erection job by Reliance, the requirement of
E6013 electrode shall be 2500 x (45/75) Ton i.e. 1500Kg
So total requirement of E6013 electrode for Reliance is 4000Kg
Keeping 25% extra for MPC and O&M requirement, the total requirement of E6013 electrodes
is 5000Kg. This shall be split into 3:6:1 ratio for 2.5mm, 3.15mm and 4.0mm dia electrode.
Accordingly, the minimum stock level to be kept at CMC stores for E6013 welding electrode
shall be as follows:

AWS Class

Dia (mm)

Matcode

Quantity

E6013

2.5

AWE60132.5

1500Kg

E6013

3.15

AWE60133.15

3000Kg

E6013

4.0

AWE60134

500Kg

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 10 of 15

Reliance
Annexure-3
Estimation of E6013, E6010, E7018, ER70S-2 & EWTh-2 based on
Procedure for reconciliation of welding consumable (200JEPME029)
Assumptions:

Average wall thickness of pipe 9.53mm

In PFS, the welding productivity is 600-800dia./day (Considering only one PFS is

functioning for welding activities).

For FCO job executed by Reliance (where welding consumable is under the scope of
Reliance) at site, the welding productivity is 1000 dia/day

For FCO/maintenance job executed by MPC/O&M team (where consumable supply is under
scope of Reliance) at site, the welding productivity is 500 dia./day

In SMAW process, 15% welding electrode is used for E6010, balance 85% for E7018

In GTAW process, 1 EA of 2%Thoriated Tungsten rod (EWTh-2, 2.4mm x 150mm length) is

consumed against 1Kg of filler wire.

As E7018 and ER70S-2 items are generally procured from Indian vendors, the lead time
for procurement of is 45 days.

As E6010 and EWTh-2 items are generally procured from foreign vendors, the lead time for
procurement is 75 days.

80% welding shall be carried out by SMAW, balance 20% by GTAW

1) E7018 electrode:
Total welding productivity per day is 2300 inch dia. Since 80% of the total job is carried out by
SMAW process alone, scope of SMAW is 1840 inch dia per day.
SMAW electrode consumption is (112+135)/2 i.e. 123.5gm per inch dia.
Accordingly E7018 electrode consumption is 123.5x0.85 i.e.105gm per inch dia.
So E7018 electrode consumption is 193Kg/day.
For 45 days the total requirement of E7018 is 8694Kg
The same can be split in to 30:60:10 as follows:

2.5mm

2608Kg

3.15mm

6085Kg

4.0mm

870Kg

2) ER70S-2 GTAW filler wire:

Total welding productivity per day is 2300 inch dia. Considering 20% of welding shall be
carried out by full GTAW process.
Total scope of work under GTAW is 460 inch dia per day
GTAW filler wire consumption shall be (58+70) x 0.5 x 1.2 x 1.2 gm i.e.92 gm per inch dia.
Hence filler wire requirement shall be 460 x 92 i.e. 42.3Kg per day.
For 45 days, the filler wire requirement shall be 1904.4Kg
This can be split in 2:1 ratio as follows:

2.5mm

1270Kg

3.15mm

635Kg

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 11 of 15

Reliance
3) E6010 electrode:
Total scope of SMAW is 1840 inch dia. per day
Total SMAW electrode consumption is 123.5gm per inch dia.
E6010 consumption is 123.5x0.15 i.e.18.5gm per inch dia. of SMAW.
Accordingly E6010 electrode consumption is 1840x18.5 i.e.34Kg per day.
For 75 days, the requirement is 34 x 75 i.e. 2553Kg
Split the same into 1:1 ratio,

2.5mm

1275Kg

3.15mm

1275Kg

4) E6013 electrode:
Refer Annexture-2
5) EWTh-2 tungsten electrode:
Against 1904Kg of GTAW filler wire, the requirement is 1904EA Tungsten electrode.
Split the same into 90:10 ratio as follows,

2.4mm

3.15mm

1700EA
200EA

Accordingly the total stock level requirement shall be as follows:

AWS Class

Dia (mm)

Matcode

Quantity

E7018

2.5

AWE70182.5

2608Kg

E7018

3.15

AWE70183.15

6085Kg

E7018

4.0

AWE70184

870Kg

ER70S-2

2.4

AWER70S22.4

1270Kg

ER70S-2

3.15

AWER70S23

635Kg

E6010

2.5

AWE60102.5

1275Kg

E6010

3.15

AWE60103.15

1275Kg

E6013

2.5

AWE60132.5

1500Kg

E6013

3.15

AWE60133.15

3000Kg

E6013

4.0

AWE60134

500Kg

EWTh-2

2.4

AWEWTH22.4

1700EA

EWTh-2

3.15

AWEWTH23

200EA

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 12 of 15

Reliance
Annexure- 4
Estimation of E6013, E6010, E7018, ER70S-2 & EWTh-2 based on
welding consumable issuance data collected from CMC stores for April
2000-March 2001
Assumptions and considerations:

The data collected from CMC stores is only based on free issue items. Wherever, the
welding consumable supply is under the scope of the contractor is not covered under this
data.

This data covers total welding consumables free issued for shop & site(for FCO jobs carried
out by Reliance).

Lead time for E7018, ER70S-2 is 45 days. Lead time for E6010 & EWTh-2 is 75 days.

Proportional data obtained is multiplied with factor 1.25 to take care of inclusion of scope
of issue of welding consumables to MPC & O & M.

The data collected for the fast moving items is as follows (for last 1 year consumption):

AWS Class

Dia (mm)

Matcode

Quantity

E7018
E7018
E7018
ER70S-2
ER70S-2
E6010

2.5
3.15
4.0
2.4
3.15
2.5

AWE70182.5
AWE70183.15
AWE70184
AWER70S22.4
AWER70S23
AWE60102.5

7000Kg
12500Kg
13000Kg
590Kg
1300Kg

E6010
E6013
E6013
E6013
EWTh-2
EWTh-2

3.15
2.5
3.15
4.0
2.4
3.15

AWE60103.15
AWE60132.5
AWE60133.15
AWE60134
AWEWTH22.4
AWEWTH23

Data not available

2260Kg
4500Kg
1000Kg
840EA
Data not available

Accordingly, the minimum welding consumable stock level requirement shall be:

AWS Class

Dia (mm)

Matcode

Quantity

E7018
E7018
E7018
ER70S-2
ER70S-2
E6010
E6010
E6013
E6013
E6013
EWTh-2
EWTh-2

2.5
3.15
4.0
2.4
3.15
2.5
3.15
2.5
3.15
4.0
2.4
3.15

AWE70182.5
AWE70183.15
E70184
AWER70S22.4
AWER70S23
AWE60102.5
AWE60103.15
AWE60132.5
AWE60133.15
AWE60134
AWEWTH22.4
AWEWTH23

1094Kg
1953Kg
2031Kg
92Kg
338Kg
Nil
353Kg
703Kg
156Kg
220EA
-

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 13 of 15

Reliance
Annexure- 5
Estimation of E6013, E6010, E7018, ER70S-2 & EWTh-2 based on
welding consumable issuance data collected from CMC stores for April
2001-May 2001
Assumptions and considerations:

The data collected from CMC stores is only based on free issue items. Wherever, the
welding consumable supply is under the scope of the contractor is not covered under this
data.

This data covers total welding consumables free issued for shop & site.

Lead time for E7018, ER70S-2 is 45 days. Lead time for E6010 & EWTh-2 is 75 days.

An additional safety factor of 1.25 shall be taken into calculation, considering the inclusion
of issue welding consumable to MPC and O & M.

The data collected for the fast moving items are as follows (for April2001-May2001):

AWS Class

Dia (mm)

Matcode

Quantity

E7018
E7018

2.5
3.15

AWE70182.5
AWE70183.15

1251Kg
1692Kg

E7018
ER70S-2
ER70S-2
E6010
E6010
E6013
E6013
E6013
EWTh-2
EWTh-2

4.0
2.4
3.15
2.5
3.15
2.5
3.15
4.0
2.4
3.15

AWE70184
AWER70S22.4
AWER70S23
AWE60102.5
AWE60103.15
AWE60132.5
AWE60133.15
AWE60134
AWEWTH22.4
AWEWTH23

331Kg
245Kg
Nil
50Kg
250Kg
860Kg
820Kg
150Kg
258EA
Nil

Accordingly, the minimum welding consumable stock level requirement shall be as follows:

AWS Class

Dia (mm)

Matcode

Quantity

E7018
E7018
E7018
ER70S-2
ER70S-2
E6010
E6010
E6013
E6013

2.5
3.15
4.0
2.4
3.15
2.5
3.15
2.5
3.15

AWE70182.5
AWE70183.15
AWE70184
AWER70S22.4
AWER70S23
AWE60102.5
AWE60103.15
AWE60132.5
AWE60133.15

1172Kg
1586Kg
310Kg
230Kg
Nil
80Kg
390Kg
810Kg
770Kg

E6013
EWTh-2
EWTh-2

4.0
2.4
3.15

AWE60134
AWEWTH22.4
AWEWTH23

140Kg
400EA
Nil

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 14 of 15

Reliance
Annexure- 6
Stock level maintained during peak of QYI-1 project

AWS Class

Dia (mm)

Matcode

Quantity

E7018
E7018
E7018
ER70S-2
ER70S-2
E6010
E6010

2.5
3.15
4.0
2.4
3.15
2.5
3.15

AWE70182.5
AWE70183.15
AWE70184
AWER70S22.4
AWER70S23
AWE60102.5
AWE60103.15

6500Kg
12000Kg
2000Kg
3500Kg
500Kg
4500Kg
4500Kg

E6013
E6013
E6013
EWTh-2
EWTh-2

2.5
3.15
4.0
2.4
3.15

AWE60132.5
AWE60133.15
AWE60134
AWEWTH22.4
AWEWTH23

5000Kg
6500Kg
2000Kg
3000Kg
-

EPCMD-2-QM00-JEP-ME-034, Rev:00
Confidential Reliance. All rights reserved

Page 15 of 15