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1.0. Purpose.

This procedure describes the system of receipt, storage, handling and treatment of welding
consumable in all fabrication area of the workshop and the yard (Open Area).

2.0. Reference.

2.1. ASME Section II Part C.

2.2. EEMUA Publication No. 158 paragraph 5.3.2.
2.3. AWS D1.1 2004
2.4. ESAB Six Edition - Consumables for Manual and Automatic Welding.
2.5. GS 118-4
3.0. Responsibility.

3.1. Contractor welding engineer is responsible to issue procurement requirement,

warehousing requirement, reviewing the manufacturing test certificate, specifying
additional handling and reconditioning requirements.
3.2. The warehouse supervisor is responsible for withdrawal, handling and storage of
consumables. He is also responsible to monitor who check the temperature of oven.
3.3. The store keeper is responsible to issue welding rod, electrode and flux to the welder
or the welding operator. He is also responsible for scrapping damaged consumables.
3.4. The welding inspector is responsible for the periodic inspection or audit of stored
materials.
4.0. Warehousing.

4.1. All welding consumable will be received at the warehouse.

4.2. Then, the warehouse supervisor will issue the Consumables Receiving Inspection
Report (CRIR) which indicate batch / lot number, brand name, manufacturer, delivery
date, dimension and quantity ( See appendix-1 )
The welding engineer will check the batch certificate against specification and the
CRIR. The welding engineer will sign the certificate and CRIR for approval. A copy of

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approved CRIR will be sent to warehouse for releasing the consignment, the original
certificate and CRIR will be kept by the welding engineer.
4.3. All additional and issuance of welding consumable from storage will be carried out on
a rotation basic to ensure to correct stock rotation.
4.4. All welding consumable shall be stored in their original sealed container packing.
Each packet of welding consumable shall be stored on the pallets or shelves. The
welding consumable shall not be stacked excessively high (do not stack more than
eleven layers of electrodes ) so as will damage the packaging of the lower layers.
4.5. Unopened packets of electrode shall be stored under warm and dry conditions.
These conditions shall be maintained, 24 hours a day 7 days a week, to avoid
promoting pick up of the moisture which permeates through the packaging and be
absorbed into the flux coating. Upon receipt the main stock of consumables shall kept
and maintained in a close and dry environment with a minimum of temperature 20 oC
and a relative humidity equal to or less than 60%.

5.0. Baking, Oven and Drying for Low Hydrogen Electrode.

5.1. Low Hydrogen Electrode AWS A5.1 (E 7016-1, E 7018, E 7018-G)

The electrode shall be kept clean, dry, and properly stored. The electrode that is
damaged, damp, greasy or oxidized shall be scrapped.

After unpacking, welding electrode shall be drying to the baking oven at temperature
260oC - 350oC for minimum 2 hours and the holding oven at temperature 120oC 150oC before distribution to production area. ( Appendix-2)

Method of drying, baking and oven in accordance with electrode manufacturers

recommendation.

5.2. Electrode For Stainless Steel (E 316L-15) and Duplex Stainless Steel (E 2209-17)
The electrodes for Stainless Steel welding shall not be in contact with metal iron, iron
oxide and paints containing zinc

Drying temperature is 260oC 350oC for minimum 2 hours before use and the holding
oven at temperature 120oC 150oC before distribution to production are ( appendix-3 )

Method of drying, baking and oven in accordance with electrode manufacturers

recommendation.

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6.0.

Distribution of Low Hydrogen, Stainless Steel and Duplex Stainless Steel Electrode
for Production.

6.1

Issuance of the welding electrodes for production from the holding oven shall be placed in
the quiver, no welding electrodes held in the hand.

6.2

It is the Supervisors or foremans responsibility that the welder and welding operator obtain
the correct consumable as indicated on the approved Welding Procedure Specification and
that they handle, store and return in accordance with this procedure.

6.3

Soon after the quiver is distributed to the production area, the quiver shall be heated to
70oC to 100oC

6.4

After 4 hours, the remaining of unused electrodes in the quivers shall be returned for redrying and immediately marked silver paint to indicate Cycle 1 finished (see appendix2&3). After re-drying, the welding electrode shall be transferred to the holding oven and the
baking oven. The temperature and duration time of re-drying, oven and baking are same
as the temperature of Cycle 1.

6.5

Distribution for Cycle 2 use same procedure as Cycle 1. The welding electrode with
silver marking shall be priority over the new welding electrode.

After 4 hours, the

remaining of unused electrodes with silver marking in the quivers shall be returned to the
store keeper and immediately marked red paint for scrapping.
6.6

Low Hydrogen, Stainless Steel and Duplex Stainless Steel electrode have been directly
contacted with water shall be definitely rejected and removed from the site.

7.0.

Vacuum Pack Electrode ( E 2209-17, E 7016-1, E 7018,E 7918-G )

7.1. During Cycle 1, the welding electrodes from vacuum pack do not need drying before use,
because it is provided with the undamaged package, indicated by vacuum in the
package.The welding electrode in vacuum pack will not pick up any moisture during
storage. During handling protect vacuum pack from damage at all times.
7.1. Issuance of the welding electrodes for production from the holding oven shall be placed in
the quiver, no welding electrodes held in the hand.
7.3 Soon after the quiver is distributed to the production area, the quiver shall be heated to
70oC to 100oC
7.4. After 6 hours, the remaining of unused electrodes in the quivers shall be returned for redrying and immediately marked silver paint to indicate Cycle 1 finished (see appendix-2).

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For Stainless Steel and Duplex Stainless Steel, the remaining of unused electrodes in the
quivers shall be returned for re-drying and immediately marked silver paint to indicate
Cycle 1 finished after 12 hours (see appendix-3)
7.5. For distribution of Cycle 2 shall use same method as appendix-2 & 3

8. Solid Wire (ER 2209)

8.1.

The wire shall be identified with brand name and lot number.

8.2.

The wire shall be kept clean, dry and free from damage, damp, and grease.

8.3.

Wire to be cleaned or degreased prior to being used.

8.4.

All wire shall be protected from weather and stored in accordance with manufacturers
recommendation.

8.5.

Unidentified wire, showing signs of contamination and rust damage shall not be used and
shall be discarded.

8.6.

All unused wire shall be identified, covered and returned to the warehouse, unless it to be
used by continuing shift.

8.7.

The wire for Stainless Steel, Duplex Stainless Steel and Carbon Steel shall be separated
storage.

9. Flux for Submerged Arc Welding (OK Flux 10.71, OK Flux 10.62)

9.1. The flux shall be kept clean, dry and free from damage, damp, and grease before use
9.2. Unopened flux bag must be stored under warm, clean from foreign materials and dry
conditions and maintained 24 hrs a day 7 days a week. The relative humidity of the
storage is not exceeding 70 %.
9.3. During and after welding, flux may be recovered. The un-melted flux will be sieved to
remove all coarse particle, fuse flux, mill scale, dirt or other foreign matter.
9.4. The flux will be reused as necessary during each welding period or added with new flux
as required.
9.5. The remaining of flux in the opened bags or flux hopper should be stored at a
temperature at 150 25C. ( Appendix-4 )
9.6. If the fluxes have for some reason become wet, it shall be scrapped.

10. Appendixes.

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Appendix-1
PT. GUNANUSA UTAMA FABRICATORS

CONSUMABLE RECEIVING INSPECTION REPORT

Purchase Order
Supplier
Specification / Class
Description
Initiated By

:
:
:
:
:

Item No.

Class
Quantity
Data

:
:
:

* Condition
Material
MFG Brand

Size

Manufacture

Reported by
Sent to Welding
* Engineer

Date

Material Agree with Manufacturer

Documentation
Manufacturer Doc. Agree with Ordering
Requirement
Non-Conformances
Disposition of Non-conformance

:
:

Material release for fabrication

By
Copy to Store Room

:
:
:

Lot/Batch/Marking

Quantity

Yes

No

Yes

No

Date :

* If not acceptable : Quarantine and Contract Welding Engineer

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Appendix-2
FLOW CHART FOR ELECTRODES DISTRIBUTION
CARBON STEEL LOW HYDROGEN TYPE (E 7016-1, E 7018, E 7018-G)

RECEIVING
CHECK

ELECTRODE STORAGE
AREA CHECK
START
CYCLE-1

START
CYCLE-1

(***)
(*)

BACKING OVEN
260OC-350oC HOURS MINIMUM

HEATEDQUIVER
70oC-100oC

(****)
HOLDING OVEN
120oC-150oC

WELDING OPERATION
CONSUMED

EXPOSED
ATMOSPHERE

HEATED
QUIVER (s)

START
CYCLE-1

WELDING OPERATION
CONSUMED

(**)
T > 6 HOURS

MARK BY SILVER
PAINT
EXPOSED
ATMOSPHERE

SURPLUS
RETURN
T > 4 HOURS

START
CYCLE-1
MARK BY RED
PAINT
START
CYCLE-1

(*) GS 118-4
(**) Essab Recommendation
(***) Essab Recommendation & AWS D1.1
(****) Essab Recommendation

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DISCARDED /
SCRAPPED
MARK BY SILVER
PAINT

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Appendix-3
FLOW CHART FOR ELECTRODES DISTRIBUTION
STAINLESS STEEL (E 316L-15) AND DUPLEX STAINLESS STEEL (E 2209-17)

RECEIVING
CHECK

ELECTRODE STORAGE
AREA CHECK
START
CYCLE-1

START
CYCLE-1

(***)
(*)

BACKING OVEN
260OC-350oC HOURS MINIMUM

HEATED QUIVER
70oC-100oC

(****)
HOLDING OVEN
120oC-150oC

WELDING OPERATION
CONSUMED

EXPOSED
ATMOSPHERE

(**)

START
CYCLE-1

HEATED
QUIVER (s)

WELDING OPERATION
CONSUMED
T > 12 HOURS

MARK BY SILVER
PAINT
EXPOSED
ATMOSPHERE

SURPLUS
RETURN
T > 4 HOURS

START
CYCLE-1
MARK BY RED
PAINT
START
CYCLE-1
DISCARDED /
SCRAPPED
(*) Essab Recommendation
(**) Essab Recommendation & AWS D1.1
(***) Essab Recommendation

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MARK BY SILVER
PAINT

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Appendix-4

Flow Chart for Handling of Flux of Submerged Arc Welding

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