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MSW/002/2008
TANJUNG TABALONG 2x30 MW COAL FIRED POWER
PT. MAKMUR SEJAHTERA WISESA
PT. PUNJ LLOYD INDONESIA
PT INDONESIA MARINE
BRW
A
MA
21-6-10
NAME DATE
PREPARED
REV
BRW 21-6-10
RH
21-6-10
NAM DATE NAME DATE
E
CHECKED
CHECKED
PT. IM
NAME DATE
APPROVED
REVISON / DOC.
STATUS
PT.PLI
DOCUMENT TITLE
TT-PLL-M-00000-0605
Page
1 of 11
THIS DOCUMENTIS THE PROPERTY OF PT. PLI AND MUST NOT BE COPIED IN WHOLE OR PART OR LENTOUT WITHOUT
THEIR WRITTEN PERMISSION
TABLE OF CONTENTS
COVER PAGE.................................................................................................................................. . 1
TABLE OF CONTENT....................................................................................................................... . 2
1.0 PURPOSE .................................................................................................................................... 3
2.0 SCOPE.......................................................................................................................................... 3
3.0 REFERENCE................................................................................................................................... 3
4.0 DEFINITION.................................................................................................................................... 3
5.0 RESPONSIBILITIES........................................................................................................................ 3
6.0 WELDING CONSUMABLE CONTROL REGISTER........................................................................3
7.0 DOCUMENTATION / ATTACHMENT............................................................................................... 6
7.1 FLOW CHART FOR ELECTRODE DRYING AND RECONDITIONING...................................7
7.2 FORMATS................................................................................................................................ 8
1.0
PURPOSE
The purpose of this procedure is to establish a system of control for the receipt, handling,
and usage of welding consumables.
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2.0
SCOPE
The scope of this procedure is applicable to all welding consumables, electrodes, Filler
wires, etc used for piping, tank and structural welding for the project.
3.0
4.0
REFERENCES
: Process Piping
DEFINITION
WPS
5.0
6.0
RESPONSIBILITIES
5.1
Store keeper shall be responsible for the receipt, storage and issue of all welding
consumables.
5.2
PT. Indomarine QA/QC and PT. Punj Lloyd QA/QC shall be responsible to ensure
that the brand of welding consumables is same as used for qualifying the respective
Welding Procedure Specification. Change in brand of the welding consumables shall
be subject to the approval from the Engineer.
5.3
5.4
QA/QC / Welding Inspector shall be responsible for the selection of the welding
consumables, documentation and overall monitoring of the correct implementation
of the consumable management.
5.5
5.6
Welder shall be responsible for the correct use of welding consumable as per
Relevant WPS, ensure consumable which are damaged / deteriorated are not put to
use.
6.2
PT. Indomarine Store Keeper shall receive the welding consumables and
confirm the type, quantity and size against the supplier delivery note. He shall
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also check for damages to the packing and ensure that the damaged and
deteriorated welding consumables are not received.
The store keeper shall keep the Welding Inspector informed of the receipt of the
shall be strictly observed and ensure that all consumables to be used are
received on site together with their manufacturer original packing and
instruction.
All consumables found without original packing ( clearly identifiable ) will not be
accepted.
Any consumables (Electrode / wire / gas bottle ) which is unmarked or showing
signs of damage or deterioration shall be discarded.
6.3
CONSUMABLE STORAGE
All welding consumables shall be stored in accordance manufacturers instructions.
Electrodes shall be stored in clean dry conditions, in their original unopened
packing.
PT. Indomarine shall store all the welding consumables in store house, off the floor,
in rack specially allocated for welding consumable storage where the
temperature and humidity shall control. It should ensure that the consumables
are kept in a area of clean and free from grease, Oil and rust. Also shall provide
labels on the consumables storage racks to identity different types and sizes for
easy identification and retrieval.
All welding consumables shall be kept in store house. Different grades of electrode
shall be stored separately. No welding consumables shall be stored by welders
except during job. Each Electrode shall be distinguished with proper
identification or code mark.
6.4
CONSUMABLE BAKING
Baking of Electrodes before use, wherever recommended by the manufacturer
(especially for low hydrogen electrodes) shall be carried out as per
manufacturers recommendation. Maximum number of times electrode can be
baked shall not exceed the manufacturers recommendations.
Baking shall be carried out in electrically heated ovens, which are calibrated and
shall have temperature controls. Store keeper shall arrange to store different
grades of electrodes in different trays with identification labels in the oven, to
avoid mix up and wrong use of electrode. The baking temperature shall be as
per manufactures recommended instruction ( normally 300 - 350 C for 2
hours )
Shall have proper heating ovens of sufficient size to facilitate uniform drying of the
electrode with accurate temperature control as necessary. After completion of
baking, the electrode shall be stored in a holding oven at the recommended
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temperature (normally 100 - 120 C), before being used for use. Baking and
holding of electrodes shall be carried out in different ovens.
Heated Electrodes shall be directly transferred to welders heated quivers,
maintained at 100 C minimum. Electrodes kept in quivers for more than 8
hours shall be sent for re-baking. The issue of electrode from holding oven shall
be based on FIFO (First In First Out) circle. This shall be the responsibility of
the concerned store keeper and welder.
Daily temperature checks shall be carried out on baking and holding ovens and
recorded in Welding Consumable Control Register along with batch
certificate number and other details of welding consumables.
6.5
The store keeper shall issue electrodes to the welder accordingly and enter the
batch certificates numbers details of the consumable issued in the same format
as a record.
Welding Foreman shall arrange for baking and holding of the consumables
requiring baking. The baked consumables shall be issued by the welding
Foreman directly from the holding oven to the welders quivers maintained at a
minimum of 70 C or as recommended by electrode manufacture. The welders
shall ensure that their quivers are working and lids are closed after during
welding. Also ensure only one type of electrode is stored in their quivers at a
time.
The Welding Foreman and the welders shall ensure that the type of
consumable used is as per the relevant WPS and also that the electrode in use
are identifiable during all stages of use. Electrodes have identification
(Electrode grade/type and brand) stencilled at the stub end TIG Filler wires
have the filler wires name embossed at the ends.
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Welders shall ensure that the unused electrodes are returned to the Foreman at
the end of the days work and the Foreman shall suitably return them to the
store for reuse / scrap. (Electrodes which have already been baked for the
maximum no. of times allowed by the manufacturer shall be scrapped). Welders
shall not use consumables found damaged, wet, unidentified, rusted and shall
return the same to the Welding Foreman for return to the stores for scarping or
quarantine.
7.0
6.6
Low Hydrogen electrodes shall be used within 8 hours when stored in quivers.
6.7
No electrodes shall be left lying around the site/workshop. Electrodes so left shall be
scrapped and removed.
6.8
DOCUMENTATION / ATTACHMENT
7.1
7.2
Formats
7.2a Welding Consumable Baking Control register ( Form : )
7.2b Consumable Issue Control Form ( Form :.)
7.2c Electrode Batch Certificate Record ( Form. :..
7.1
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RE-BAKE ELECTRODES
IN OVEN AT 300-350 C
for 30 60 MINUTES TIPS
PAINTED AND RE-BAKE
ONCE ONLY
HOLDING OVEN
WELDING
ACTIVITIES + HEATED QUIVERS
70C MIN.
BAKED AT 300-350 C
for 30 60 MINUTES
DISCARD
UNUSED ELECTRODES
CELLULOSA / RUTILE
ELECTRODES
(From Storage)
WELDING ACTIVITY
Form MIS
Weld Consumable Request
Issue Requisition Form
7.2 Formats
7.2a Welding Consumable Baking Control register ( Form : FS-751-06-026_1R0 )
7.2b Consumable Issue Control Form ( Form : FS-751-06-026_2 R0 )
7.2c Electrode Batch Certificate Record ( Form. : FS-751-06-026_3R0 )
DOC. NO. : TT-PLL-M-00000-0605
REV.
: A
DATE
: 21-06 2010
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7.2c
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