CONSUMABLES

CONTROL PROCEDURE

DOCUMENT NO.: AZ/CCP/JFJS-788

REV. No.: 00

NO. OF PAGES: 13

CONTRACT NO: TBA

AL ZAMIL JOB NO: JF/JS-788

PROJECT NAME: KHURAIS AL CRUDE INCRIMENT-300 MBCD,

KHURAIS, K.S.A

CLIENT: AL FANAR CONSTRUCTION(AFC)

COMPANY: SAUDI ARABIAN OIL COMPANY

 AL-ZAMIL METAL WORKS FACTORY
P.O. BOX 13168, JEDDAH CITY 21493
KINGDOM OF SAUDI ARABIA
TEL. 02-638-0766, FAX 02-638-0768

CONSUMABLES CONTROL PROCEDURE

0 05-11-2016 For approval M.A.R U.F M.S.I

REV DATE DESCRIPTION PREPD CHKD APPD

REVISIONS
DOCUMENT / DRAWING NO. TOTAL NO. OF SHEETS
(INCLUDING COVER)
AZ/CCP/JFJS-788
13
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Consumables Control Procedure

INDEX

1. SCOPE

2. PURPOSE

3. REFERENCES.

4. DEFINITIONS

5. RESPONSIBILITY AND AUTHORITY

6. SHIELDING GAS

7. CONSUMABLES ISSUE AND RETURN CONTROL

8. CERTIFICATION

9. STORAGE, CONDITIONING AND EXPOSURE OF WELDING

CONSUMABLES

10.CALIBARTION /VALIDATION

11.ATTACHMENTS:
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Consumables Control Procedure

1. SCOPE:
This document gives requirements for welding consumable controls intended to use for
fabrication and erection of CS tanks for

PURPOSE:

The purpose of this procedure is to define minimum requirements for the storage, handling,
identification, conditioning, and issue and return of welding consumables and assign
corresponding responsibilities.

2. REFERENCES:

API-650
UL-142
ASME Sec II Part C
ANSI/AWS specifications

3. DEFINITIONS:
AZMWF: Al-Zamil Metal Works Factory
CONTRACTOR: Al Fanar Construction(AFC)
COMPANY: Saudi Arabian Oil Company (ARAMCO)

4. RESPONSIBILITY AND AUTHORITY:

Welding engineer will be responsible to:

• Review (MSI) or purchase requisition to ensure correct consumables are purchased against
the approved WPS.

• Review the consumables batch certificate against (MSI or PR) prior to release. Assess
disposition where packaging damage observed.

• Establishes re-order to ensure there is no shortage during construction.

• Supervises consumables room personnel and operations to comply with the consumable
condition and instruction.

• Material service indent inspector shall do the quality inspection for the welding consumables
upon delivery and sign the Material Receiving Report-MRR (Exhibit-16).

• Establishes re-order levels to ensure there is no shortage during welding works or

construction.
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Consumables Control Procedure

• Develop color coding system for return electrodes.

• To create a list of welders with their qualification process and submitted to the welding
foreman and welding consumable storekeeper for distribute the welding electrodes
accordingly for each job.

• Issue the approved WPS and welding map to the welding foreman.

Welding inspector will be responsible for:

• Carrying a daily inspection/audit for consumables at the welding areas to ensure it complying
with requirements for each job.

• Frequently monitor the welding quivers temperature on site and shop and the calibration
validity.

Welding foreman will be responsible for:

• Monitor the welding handling of consumables at site and production shop to ensure it is in-
line with job requirements and approved WPS.

• Ensure the welding quivers are properly used and kept closed by welders at all times.

• To ensure the welding electrodes are been issued to welders whom are qualified /certified to
perform the welding work according to the list provided by the welding engineer/inspector
and approved WPS.

• Ensure the welding electrodes are returned at the end of each shift and examine them to make
sure any wet or damaged items are discarded.

• Authorizing the welding consumables to welders

Welding consumable storekeeper will be responsible for:

• Maintain an effective control and storage of welding consumable

• Ensure the welding electrodes are issued according to the welders list provided by welding
engineer for each job.

• Maintaining the electrode issuance and return log against each request.
(Attachment 1)

• Maintain electrode baking register (attachment 2).

• Maintain welding consumable authorization slip (attachment 3).

• Maintain Equipment/tools borrower receipt sheet (attachment 4).

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Consumables Control Procedure

5. SHIELDING GAS:

Shielding Gases shall conform to AWS 5.32

6. CONSUMABLES ISSUE AND RETURN CONTROL:

6.1. ISSUE FROM STORE:

a. At the beginning for each shift, the welding foreman will request the applicable electrode type,
size, and quantity required according to the approved WPS.

b. Welding consumables shall be stored and issued on a “First-in, First-out” basis and segregated
according to the brand name, size, and specification.

c. In order to issue new electrodes (used electrodes shall be returned back to welding consumable
storekeeper.)

d. Welders shall be supplied with electrodes RODS with quantity may be consumed within the
same working day of 25 pieces as maximum.

e. Welding electrodes shall be issued only to the individual welders responsible for performing
the welding work according to the submitted list.

6.2. RETURN TO STORE:

a. At the end of each shift or day welding foreman shall ensure all unused electrodes are returned
to welding consumable store.

b. Welding consumable storekeeper shall ensure all returned electrodes are marked in Yellow or
Red color prior to place them in the holding oven.

c. Returned flux shall be re-baked, prior to re-issue.

7. CERTIFICATION:

Material certification of welding consumables shall be 3.1 for pressure parts

8. STORAGE, CONDITIONING AND EXPOSURE OF WELDING CONSUMABLES

8.1. Basic Coated Low Hydrogen Type

These electrodes shall be placed in a holding oven no more than 4 layers deep and held at 120
– 150 degrees C until they are required in production.
Welders will remove these electrodes from the holding oven and place them directly into a
heated electrode quiver which has previously been verified to achieve a temperature of at least
100 degrees C.
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Consumables Control Procedure

A welder shall only remove one type of electrode from the holding oven at any one time and
shall only have one type of electrode in his quiver at any one time, each welder is
responsible for the maintenance of his electrode quiver.
Only a sufficient quantity of electrodes shall be removed from the holding oven for a 4 hour
period, the electrodes however are permitted to remain in the electrode quiver for up to 8
hours provided the quiver remains at 100 degrees C at all times.
Electrodes that have been exposed to the atmosphere for more than 0.5 hours, and electrodes
that have become damp or wet shall be discarded.
8.2. Stainless Steel And Non Ferrous Type

These electrodes shall be placed in a holding oven no more than 4 layers deep and held at 120
– 150 degrees C until required in production.
Welders will remove these electrodes from the holding oven and place them directly into a
heated quiver which has previously been verified to achieve a temperature of at least 100
degrees C.
A welder shall remove only one type of electrode from the holding oven at any one time, and
shall only have one type of electrode in his quiver at any one time, each welder is responsible
for the maintenance of his electrode quiver.
Only a sufficient quantity of electrodes shall be removed from the holding oven for a 4 hour
period, the electrodes however are permitted to remain in the electrode quiver for up to 8
hours provided that the quiver remains above 100 degrees C at all times.
Electrodes exposed to the atmosphere for more than 0.5 hours, and electrodes that have
become damp or wet shall be discarded.
8.3. Submerged Arc Wires

All wires shall be stored on a pallet in warm dry conditions until required in production, they
shall remain in the manufacturers packaging with the proper identification attached.
Wires of the same classification and size shall be stored together, any product showing signs
of contamination shall be discarded.
8.4. Gas Tungsten Arc Wires

All wires shall be stored on a pallet in warm dry conditions until required in production, they
shall remain in the manufacturers packaging with the proper identification attached.
Wires of the same classification and size shall be stored together, any product showing signs
of contamination shall be discarded.
8.5. Gas Metal Arc & Flux Cored Arc Wires

All wires shall be stored on a pallet in warm dry conditions until required in production, they
shall remain in the manufacturers packaging with the proper identification attached.
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Consumables Control Procedure

Wires of the same classification and size shall be stored together, any product showing signs
of contamination shall be discarded.
8.6. Submerged Arc Fluxes

All welding flux shall remain in the manufacturers packaging and be stored on a pallet in the
warehouse until required, once in the workshop it shall be kept in a holding oven at a constant
temperature of at least 100 degrees C until used during the welding cycle
It is essential that when removing welding electrodes or flux from the holding oven the
required information is accurately filled out in the Welding Electrode and Flux Issuance
Record and that these are reviewed by the Quality Control Dept on a regular basis.

9. CALIBARTION /VALIDATION

All backing, holding, Oven and Quivers shall be Calibrated or Validated every
year to check the conformity.
The Calibration or Validation sticker (attachment in Para 13.5) shall be pasted on the
Equipment after each Calibration or Validation process.
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Consumables Control Procedure

TABLE # I
Permissible Atmospheric Exposure of
Low – Hydrogen Electrodes
Notes: ELECTRODE HOURS
For A5.1, the Exposure may be extended to 8 A5.1
hours if the electrodes are continuously stored E70XX 0.5 Max.
in portable electrode oven heated to 100oC E70XXR 0.5 Max.
minimum. E70XXXHZR 0.5 Max.
E7018M 0.5 Max.
For A5.5, the exposure time may be doubled A5.5
(to 4 hours and 1 hour respectively if the E70XX-X 0.5 Max.
electrodes are continuously stored in a E80XX-X 0.5 Max.
portable electrode oven heated to 100oC E90XX-X 0.5 Max.
minimum). E100XX-X 0.5 Max.
E110XX-X 0.5 Max.
10. ATTACHMENTS:

15.1. Welding Consumable issue/return log (Attachment 1).

15.2. Electrode baking registers (attachment 2).
15.3. Welding consumable authorization slip (attachment 3).
15.4. Calibration Record (attachment 4).
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Consumables Control Procedure

Attachment # 01
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Consumables Control Procedure

Attachment # 02

ELECTRODE BAKING REGISTER Page No.:

Oven Serial No. : Oven Location :

Date Time in Time Temp-°C Electrode Size- Qty-kg Batch Signature
out Class mm No.

Form: AZ-STOR-10, Rev: 0

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Consumables Control Procedure

Attachment # 03

WELDING CONSUMABLE
ISSUE/RETURN LOG Page No.:

Issued Returned
Date Time Electrode Class Size-mm Batch No. Welder ID Job No.
Qty(Nos) Qty(Nos)

Form: AZ-STOR-09, Rev: 0

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Consumables Control Procedure

Attachment # 04