RESID FLUID CATALYTIC Doc. No.
:
CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
PT. PERTAMINA (PERSERO)
Rev. No. : 0
WELDING MATERIAL CONTROL Page : 2 / 12
PROCEDURE
PROJECT : RESID FLUID CATALYTIC CRACKING (RFCC) PROJECT
LOCATION : PERTAMINA RU-IV CILACAP, CENTER OF JAVA
PERTAMINA : PERTAMINA (PERSERO)
CONTRACT NO. : 15/C00000/2011-S2
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RESID FLUID CATALYTIC Doc. No. :
CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
PT. PERTAMINA (PERSERO)
Rev. No. : 0
WELDING MATERIAL CONTROL Page : 3 / 12
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0 ISSUED FOR APPROVAL NI YC SI
REV. DESCRIPTION DATE PREPARED REVIEWED APPROVED
BY BY BY
REVISION HISTRORICAL SHEET
REV. PAGE / ITEM DESCRIPTION OF CHANGE
PARAGRAPH
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RESID FLUID CATALYTIC Doc. No. :
CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
PT. PERTAMINA (PERSERO)
Rev. No. : 0
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Table of Contents
Section Title
1.0 SCOPE
2.0 REFERENCES
3.0 TERMS AND DEFINITIONS
3.1 Contractor
3.2 SubContractor
3.3 Drying (Baking)
3.4 Keeping (Warming)
3.5 Re-drying
3.6 Unusable Electrodes
4.0 RESPONSIBILITIES OF THE SUBCONTRACTOR
5.0 RESPONSIBILITIES AND RIGHTS OF CONTRACTOR
6.0 RESPONSIBILITIES OF WELDING MATERIAL CONTROLLER
7.0 WELDING MATERIAL CONTROL
8.0 CONTROL OF STORAGE
8.1 Warehouse
8.2 Storage Conditions
9.0 CONTROL OF DRYING AND HOLDING
9.1 Equipment for Drying
9.2 Control of Drying, Re-drying and Holding
10.0 WELDING MATERIAL REQUEST CONTROL
11.0 CONTROL OF DELIVERY OF WELDING MATERIAL
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RESID FLUID CATALYTIC Doc. No. :
CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
PT. PERTAMINA (PERSERO)
Rev. No. : 0
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12.0 RETURN OF WELDING ELECTRODE TO THE SHOP
13.0 IDENTIFICATION OF WELDING MATERIAL
14.0 APPENDIXES
1.0 SCOPE
This document provides the standard practice for controlling the welding materials
(welding electrode and rod) to maintain the sufficient quality of welds in the welding
of construction work including shop fabrication of structural, piping and Tank at field
for Resid Fluid Catalytic Cracking (RFCC) Project.
2.0 REFERENCES
The latest edition of following code / standard shall be referred as a part of this
specification:
AWS D1.1 : Structural Welding Code
ASME Section II Part C : Specification for Welding Rods, Electrodes,
and Filler Metals
3.0 TERMS AND DEFINITIONS
3.1 Contractor
Contractor shall mean consortium of PT. Adhi Karya Tbk and GS Engineering
& Construction
3.2 Subcontractor
Subcontractor shall mean a firm / construction company who is awarded the
contract by Contractor to execute construction activities.
3.3 Drying (Baking)
Prior to issue the specified low hydrogen electrodes for carbon steel, low
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CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
PT. PERTAMINA (PERSERO)
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alloy steel and austenitic stainless steel, they shall be dried to reduce the
humidity contained in the coated flux in accordance with Appendix -1 “Drying
Conditions of Electrodes.” Drying of electrodes shall be in accordance with
the manufacturer’s recommendation.
3.4 Keeping (Warming)
After drying, the electrodes mentioned above shall be kept at a temperature
range of 100 0C –140 0C or shall be in accordance with manufacturer’s
recommendation in the holding oven to prevent them from absorbing
additional humidity / moisture.
3.5 Re-drying
Electrodes that had been issued for use but have not been used within that
day shall be re-dried in accordance with para. 3.3 but no more than one
time.
3.6 Unusable Electrodes
Means used electrodes or unused electrodes that have defects, such as lack
of flux, wet flux or change in quality of flux. Electrodes that have been re-
dried and still remain unused on the next issuance day are considered
unusable electrodes.
4.0 RESPONSIBILITIES OF THE SUBCONTRACTOR
(1) The Subcontractor shall be wholly responsible for controlling welding
material which includes receiving, storage, drying, keeping, issue, return, re-
drying and re-issue of welding materials.
(2) The Subcontractor shall establish its own welding material control procedure
based on this practice and shall submit it to Contractor to obtain approval
prior to the commencement of any welding work.
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CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
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(3) The Subcontractor shall establish a centralized welding material storage and
control room, which may be located inside its warehouse or site workshop.
Appendix-2 provides an example. In addition, a satellite welding material
control crib may be provided at site, if necessary.
(4) The Subcontractor shall provide and maintain all necessary equipment and
facilities for welding material control, such as drying and keeping ovens,
portable dryer (quiver) to each welder, Gas Tungsten Arc Welding (GTAW)
rod box or container to each welder, and so on.
(5) The Subcontractor shall assign a full time Welding Material Contoller(s),
hereafter called WMC in charge of the above activities and under the
supervision of the Subcontractor’s QC or welding engineer.
(6) The Subcontractor shall be responsible for all welding material control during
daily production welding at both site and workshop location. This includes
the correct usage of each type of welding electrodes/rods, provision of a
portable dryer (quiver) to each welder and its handling, daily house-keeping
after welding work so as to clear all used and unused welding
electrodes/rods from site and workshop, etc.
(7) The Subcontractor shall be responsible for estimating the total required
quantity of each type of welding electrode and rod for the project,
procurement of them from a Contractor approved manufacturer(s), periodical
inventory checks and additional procurement during the construction stage
in order to secure the construction schedule and avoid shortage of welding
materials at the construction site. When requested by Contractor, the
Subcontractor shall submit its procurement plan and welding material
inventory status to Contractor for information.
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CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
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5.0 RESPONSIBILITIES AND RIGHTS OF CONTRACTOR
(1) Contractor shall review the Subcontractor’s welding material control
procedure and approve it prior to the commencement of welding work.
(2) Contractor shall check the Subcontractor’s welding material control room
and facilities prior to the commencement of welding work.
(3) Contractor has the right to monitor and check implementation and
effectiveness of the Subcontractor’s welding material control at any time and
to provide advice or instructions on the same and require its improvement.
(4) Contractor shall perform spot checking of welder’s portable dryers (quivers)
to confirm that proper keeping and warming conditions are applied, the
correct usage of each type of welding material, and confirm that welding
work is performed by welders qualified for the material being used.
6.0 RESPONSIBILITIES OF WELDING MATERIAL CONTROLLER
(1) Welding Material Controller shall have sufficient knowledge of each type of
welding electrode and rod to be used for the project in order to prevent
mixing and/or mis-issue, and to carry out proper storage and drying of
electrodes.
(2) Welding Material Controller shall be responsible for welding material control
including storage, drying, keeping, re-drying and issuing in accordance with
the established procedure and under the supervision of the Subcontractor’s
QC or welding engineer.
7.0 WELDING MATERIAL CONTROL
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CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
PT. PERTAMINA (PERSERO)
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Subcontractor shall submit material certificate of welding electrodes and rods to
Contractor for review and approval. Subcontractor shall submit the detail plan for
the welding material control to Contractor for approval prior to commencement of
welding work, which consists of the following items:
1) Organization and responsibilities.
2) Work flow chart or description of control sequence.
3) Numbers of welding material controllers.
4) Layout plan of welding material control room.
The welding material control system shall be monitored periodically by Contractor’s
Inspector during Subcontractor’s operation.
8.0 CONTROL OF STORAGE
8.1 Warehouse
Welding electrodes and rods shall be stored in a separate place in
warehouse. Welding electrodes and rods shall be stored orderly and
separately with labels or marking so that they can be identified easily to
avoid mixing.
8.2 Storage Conditions
Storage conditions of welding material shall be as follows:
(1) Package of welding electrodes and rods shall be kept away from any
humidity.
(2) Package of welding electrodes and rods shall not be stored directly
on the ground.
(3) Package shall not be opened until just before use.
(4) Welding materials storage shall be in such way that older stocks are
issued first.
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CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
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(5) All GTAW filler wires shall be de-greased prior to use.
9.0 CONTROL OF DRYING AND HOLDING
9.1 Equipment for Drying
(1) Drying Oven
Drying oven is used for drying and re-drying of the electrodes that conform
to the requirements of para. 3.3. Considering the capacity of each drying
oven and the total quantity of welding electrodes to be used in one day,
drying ovens shall be able to consistently control the drying temperature and
holding time. Oven, dryers, quivers shall be calibrated every 3 months.
(2) Holding Oven
Holding oven is used to maintain storage temperature of welding electrodes
that conform to the requirements of par. 3.4. Sufficient numbers of holding
ovens shall be provided considering the capacity of ovens and the quantity
of welding electrodes to be used.
Holding ovens shall be kept at a temperature range of 100 0–1400 C at all
times.
When the quantity of welding electrodes to be used in one day is small,
drying oven described above may be used for this purpose.
(3) Portable Dryer
Each welder shall have at least one portable dryer. Welder’s stamp number
shall be clearly marked on his portable dryer. One portable dryer shall be
limited to one type of welding electrode. During welding work, the portable
dryer should be kept warm at a minimum temperature of 70 0C.
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RESID FLUID CATALYTIC Doc. No. :
CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
PT. PERTAMINA (PERSERO)
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9.2 Control of Drying, Re-drying and Holding
Control of drying, re-drying and holding storage shall be carried out by
Welding Material Controller (WMC) in accordance with Appendix-1.
The drying oven and holding storage oven shall be clearly marked to show
the type of electrodes contained.
10.0 WELDING MATERIAL REQUEST CONTROL
When requesting welding material, Welding Foreman or Welding Supervisor shall fill
in the “Welding Material Request Card“ (hereinafter called WMRC) showing the
required type and quantity of welding electrodes and welding rods to be used for
next day by each welder, and submit it to WMC by 4 p.m. of the provisions day of
delivery.
The welder shall not request the welding material directly to WMC.
Upon receipt of the WMRC, WMC shall prepare for issuance on the next day as
follows:
(1) Check the total quantity and type of the welding materials requested.
(2) Check the stock quantity and type dried and returned / re-dried on the day.
(3) The WMC shall review the required quantity of electrodes to be dried for
delivery on the next day.
11.0 CONTROL OF DELIVERY OF WELDING MATERIAL
(1) A portable dryer shall be provided to each welder for welding electrodes
storage and keep them warm at work site and the welding electrodes shall
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CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
PT. PERTAMINA (PERSERO)
Rev. No. : 0
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be delivered into the portable dryer directly. For TIG rods, empty boxes of
TIG rod may be used.
The portable dryers shall be collected and sent to the welding material
storage area for emptying and safe keeping at the end of each working day.
(2) Supervisor or Welding Foreman shall come to the welding material control
room to receive the replenished portable dryers for each welder under his
supervision every morning.
(3) Maximum issue amount of electrodes for one delivery shall be limited to 5 kg
per each portable dryer.
(4) Electrodes which have been redried and kept for a long time shall be issued
first.
(5) Prior to delivery, WMC shall check the following points:
- Confirm the contents of the WMRC.
- Check the quantity and type of welding electrode against the request.
12.0 RETURN OF WELDING ELECTRODE TO THE SHOP
(1) Supervisor or Welding Foreman shall gather the portable dryers and TIG rod
from each welder and return to the designated place at the welding material
control room at the end of each day. No electrodes shall be left at
construction site or work shops.
(2) Prior to return the welding materials, Supervisors or Welding Foreman shall
segregate unusable electrodes and inform WMC for their disposal. When
electrodes that are not used on that day remain in the portable dryer, WMC
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CRACKING (RFCC) PROJECT RFCC-C-PR-PC-1140-006-0
PT. PERTAMINA (PERSERO)
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shall take out and stock separately for re-drying or disposal as required.
13.0 IDENTIFICATION OF WELDING MATERIAL
To avoid mixing and misuse of welding materials, all materials shall be made
identifiable with original marking or color coding after removal from its original
container.
All SMAW electrodes and GTAW rods being issued and used without original
marking shall be provided with color coding to identify their brand names or AWS
numbers.
Color code table to be used for RFCC Project shall be provided by Contractor’s
QAQCM. WMC shall be responsible to verify all electrodes and rods being correctly
color coded at the time of issuance. During production welding, Contractor’s QC
Inspector(s) and Subcontractor’s Welding Inspector (s) shall check color code /
identification marking as daily basis for correct usage.
A sample of color code table is exhibited in Appendix-5.
14.0 APPENDIXES
Appendix-1 : Drying Conditions of Electrode
Appendix-2 : Welding Material Control Room and Facilities (Example)
Appendix-3 : Flow Chart of Welding Material Control
Appendix-4 : Welding Material Request Sheets (Sample Form)
Appendix-5 : Color Code Table of Welding Rods and Electrodes (Example)
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