PROCEDURE FOR CONTROL OF WELDING

CONSUMABLES

Doc. No. : HCC-6-1-G1/CS13138

Issued for Review and Approval

C 28-05-2014 after incorporating Client's
(SAPMT) Comments on 22-04-14

Issued for Review and Approval

B 13-04-2014 after incorporating Client's
Comments

Issued for Review and

A 23-02-2014
Petrofac Saudi Arabia Limited
Approval R. Mohd. Javidh
QHSE Manger ( PSAL )
Rev. Date Description Prepared By : Approved By :

Page 1 of 9
 Doc No : HCC-6-1-G1/CS13138
Procedure for Control of Welding Page No : 2 of 9
Consumables Rev. / Date : C / 28-05-2014

CONTENTS

1. Scope

2. Reference

3. Selection and Receiving of Welding Consumables.

4. Welding Process and Filler Metal Used

5. Shielding Gas

6. Storage, Conditioning and Exposure of SMAW Electrodes, Wires &

Fluxes

7. Issuance Control of Welding Consumables

8. Marking of Electrodes or Flux Package

9. Records

10. Attachments

 Flow Chart for Control of SMAW Welding Electrode

 Attachment#1 of SAES-W-017
 Attachment#2 of SAES-W-017
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1. SCOPE

Intent of this procedure is to describe the proper storage and control of welding consumable
to satisfy the requirements of ASME, AWS , API 650,620 32-SAMSS-006,32-SAMSS-005
Codes &SAES-W-017.

2. REFERENCE

 API 650 11th Edition Addendum 3 August 2011

 API 620 11th Edition Addendum 3 March 2012
 32-SAMSS-005 (26-Jan-2011)
 32-SAMSS-006( 16 Sep-2008)
 SAES-W-017 (13 Dec 2011)

3. SELECTION AND RECEIVING OF WELDING CONSUMABLES:

3.1. Welding consumables shall be selected by Welding Engineer / Welding Inspector based on
their properties, compatibility with the materials to be joined their suitability for the intended
service. And consideration of polarity, position, and direction of welding. Welding
consumables not meeting standard industry practice using the above criteria may be rejected
by CSD. Welding consumables which are being used outside of their rated tensile or impact
ranges listed in the manufacturing specs must be batch tested or have CSD approval. Batch
testing must be in accordance with AWS A 5.01M /A5.01 to verify that they will meet the
requirements of the base material.
3.2. Electrodes, Filler wires, and fluxes shall confirm to ASME SEC II C or any other International
equivalent specification (E.g.: BSI, JIS, DIN etc.) accepted by the Committee chairman.
Approval to use consumables unlisted in ASME SEC II C or equivalent specification shall be
obtained through the welding procedure review process. For unlisted consumables, vendor
Literature which shall include intended use and approximate chemistry and mechanical
properties, shall be submitted with the procedure.
3.3. All consumables shall be stored and dried in accordance with the requirements of Para 5
3.4. GTAW filler metal shall have the AWS identification or the manufacturer’s identification
marked on each individual rod with tags, stencil or stamping.
3.5. Welding Engineer / Welding Inspector shall do the quality inspection for the welding
consumables upon delivery based on the issued Purchase Order and ASME Code for Visual
Marking ( the whole of the required marking of the applicable ASME code specification ) and
sign the Material Receiving Report (MRR).
3.6. The Welding Engineer shall review / assess the chemical and mechanical test result values
and Mill Test Certificates provided by the manufacturer and shall keep them in file for ready
reference.

4. WELDING PROCESS AND FILLER METAL USED

4.1 Shielded metal arc welding (SMAW)

 Low hydrogen electrodes (Except F-Nos. 1 and 2) shall be used for all pressure retaining
welds or attachment to pressure boundaries.
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 For carbon steel piping welded from one side only, E6010 may be used for the root pass,
for pipes equal to or greater than NPS 3” . For Carbon Steel pipes less than 3” NPS, Root
pass shall be done by ER 70S-6.

 AWS Electrode classification E6012, E6013, E6020, E6014, E7020, E7024 and E7028
shall not be used for pressure–containing welds. These electrodes, however, may be
used for non-pressure – containing welds of P-1 materials (Ex. Grating, Handrail).

4.2 Gas tungsten arc welding (TIG) :

For carbon steels, the filler metals shall meet chemical and physical test requirements of
AWS A5.18, classification ER 70S-6, ER 70S-2 or ER 70S-3.

4.3 Flux cored arc welding (FCAW) :

For carbon steel, the wires shall conform to AWS A5.20 classification E71T-1, E70T-1, E71T-
5 or E70T-5. This electrode shall be used with an external shielding gas.
4.4 Gas metal arc welding (GMAW) :
For carbon steel, Bare wires shall conform to AWS A5.18 classification ER 70S-6, ER 70S-2
or ER 70S-3.

4.5 SUBMERGED ARC WELDING (SAW) :

 For carbon steels, welding wires shall be limited to AWS classification EM-12K and EL-12
and flux shall be limited to F6A2, F7A2 and F7A4.

 SAW Fluxes that the flux manufacturer recommends for single pass welding shall not be
used for multiple pass welding.

 Active flux are not permitted.

4.6 Carbon and low alloy steel electrodes / wires that have nonspecific chemistry as indicated by
a “G” classification suffix (i. e. EXXXX–G, ERXXX–G or EXXT–G) shall not be used.
4.7 The selection of filler metals for joining similar materials shall be in according with Table #1.
4.8 The selection of filler metals for welding dissimilar materials shall be in accordance with
Table #2.
4.9 Table #1 and Table #2 refer to coated electrodes, for wire welding (SAW, GMAW, GTAW
and FCAW) use equivalent electrode classification (AWS A5.9, A5.14, A5.17, A5.18, A5.20,
A5.23, A5.28, A5.20, A5.22 and A5.29).

5. SHIELDING GAS :

 Shielding Gases shall conform to SFA 5.32, Specification for Welding Shielding Gases:
 Carbon dioxide (Co2) : Shall be as per AWS classification SG-C Shall have a minimum
purity of 99.8% and Compressed gas association CGA G-6.2Grade H.
 Argon : Shall be as per AWS classification SG-A shall have a minimum purity of 99.997%
Compressed gas association CGA – 11.1 grade C.
 Shielding Gases cylinders shall be color coded(striped) to indicate their contents
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6. STORAGE, CONDITIONING AND EXPOSURE OF SMAW ELECTRODES, WIRES & FLUXES

(Control of Welding Electrodes is illustrated in the attached Flow Chart)
a) Storage and re-bake ovens shall have a calibrated temperature gauge to continuously
monitor the temperature.
b) Portable electrode storage ovens with a minimum temperature of 120 C are considered
equivalent storage ovens. Proper use of the oven (Eg. Closed lid, continuously on while
in use) and periodic checks of the temperature achieved with each portable oven are
required.
c) Some applications may require higher drying temperature and shorter atmospheric
exposure times.
d) Low hydrogen consumables (defined as less than or equal to 8 ml of hydrogen per 100 g
of deposited weld metal, measured in accordance with AWS A 4.3) shall be used.

6.1 Low Hydrogen Electrodes to A5.1

6.1.1 Drying and Re-drying

 Prior to use all electrodes shall be dried at 260-430°C for 2 hours minimum.
 The drying step may be deleted if the electrodes are supplied in the dried condition in a
hermetically sealed metal can with a positive indication of seal integrity or vacuum
sealed package.
 Returned /unused welding electrodes for re-drying shall be color-coded in order to
ensure that re- drying will not be done more than once.

6.1.2 Storage

After drying, the electrodes shall be stored continuously in ovens at 120°Cminimum.

6.1.3 Exposure

 Upon removal from the drying or storage oven or hermetically sealed containers, the
electrodes may not be exposed to the atmosphere for more than 4 hours.
 The exposure may be extended to 8 hours if the electrodes are continuously stored in a
portable electrode oven heated to 65°C minimum.
 Electrodes exposed to the atmosphere for less than the permitted time period may be re-
conditioned.
 Electrodes exposed in excess of the permitted time period must be re-dried.
 Electrodes that have become wet or moist shall not be used and shall be discarded.

6.1.4 Re-conditioning

 Electrodes exposed to the atmosphere for less than the permitted time period may be
returned to a holding oven maintained at 120°C minimum;
 After a minimum holding period of four hours at 120°C minimum the electrodes may be
reissued.
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6.2 Low Hydrogen Electrodes to A5.5

6.2.1 Drying and Re-drying

 Prior to use all electrodes shall be dried at 370-430°C for 2 hours minimum.
 Returned /unused welding electrodes for re-drying shall be color-coded in order to
ensure that re- drying will not be done more than once.

6.2.2 Storage

After drying, the electrodes shall be stored continuously in ovens at 120°C minimum.

6.2.3 Exposure

 Upon removal from the drying or storage oven or hermetically sealed containers,
the electrodes may not be exposed to the atmosphere for more than 2 hours for
E70xx or E80xx electrodes and 30 minutes for any higher strength electrodes.
 The exposure times may be doubled (to 4 hours and 1 hour, respectively) if the
electrodes are continuously stored in a portable electrode oven heated to 65°C
minimum.
 E70xx and E80xx electrodes exposed to the atmosphere for less than the permitted time
period may be re-conditioned.
 E70xx and E80xx electrodes exposed in excess of the permitted time period must be re-
dried. Higher strength electrodes (above E80xx) must be re-dried after any atmospheric
exposure.
 Electrodes that have become wet or moist shall not be used and shall
be discarded.

6.2.4 Re-conditioning

 E70xx and E80xx electrodes exposed to the atmosphere for less than the
permitted time period may be returned to a holding oven maintained at 120°C
minimum;
 After a minimum holding period of four hours at 120°C minimum the
electrodes may be reissued.
 Conditioning and storage of electrodes and fluxes shall be done in accordance with
SAES-W-017

6.3 Stainless Steel and Non-Ferrous Electrodes

6.3.1 Drying and Re-drying

 Prior to use all electrodes shall be dried at 120-250°C for 2 hours minimum.
 The drying step may be deleted if the electrodes are supplied in the dried
condition in a hermetically sealed metal can with a positive indication of seal
integrity or vacuum sealed package. Electrodes may be re-dried only once.
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6.3.2 Storage

 After drying, the electrodes shall be stored continuously in ovens at 120-200°C

minimum.

6.3.3 Exposure

 Upon removal from the drying or storage oven or hermetically sealed containers, the
electrodes may not be exposed to the atmosphere for more than 4 hours.
 The exposure may be extended to 8 hours if the electrodes are continuously stored in a
portable electrode oven heated to 65°C minimum.
 Electrodes exposed to the atmosphere for less than the permitted time period may be re-
conditioned.
 Electrodes exposed in excess of the permitted time period must be re-dried.
 Electrodes that have become wet or moist shall not be used and shall be discarded.

6.3.4 Re-conditioning

 Electrodes exposed to the atmosphere for less than the permitted time period may be
returned to a holding oven maintained at 120°C minimum;
 After a minimum holding period of four hours at 120°C minimum the electrodes may be
reissued.
 Conditioning and storage of electrodes and fluxes shall be done in accordance with
SAES-W-017.

6.4 Non-Low Hydrogen Electrodes to A5.1 or A5.5

The electrodes shall be stored in a dry environment. Any electrodes that have become moist
or wet shall not be used and shall be discarded.

6.4.1 SAW fluxes

 Fluxes for material with a minimum specified tensile strength less than or equal
to 70Ksishall be stored in sealed containers in a dry environment.
 Opened SAW flux containers shall be stored continuously in ovens at 65°C minimum or
the manufacturer's recommendation, whichever is greater.
 Any flux that has become moist or wet shall not be used and shall be discarded.

6.4.2 SAW, GTAW, GMAW, and FCAW electrodes and wires

All electrodes and wires shall be stored in sealed containers in a dry environment. Any wires
that have visible rusting or contamination shall not be used and shall be discarded.

6.5 Non – low Hydrogen electrodes.

The electrodes shall be stored in a dry environment. Any electrodes that have become moist
or wet shall not be used and shall be discarded.
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7. ISSUANCE & CONTROL OF WELDING CONSUMABLES

7.1. Welding Foreman / Store Keeper shall issue welding consumables to the welders based on
the WPS. Issue of welding consumables shall be recorded in Electrode / Wire Issue Sheet
(Form No. HCC-6-1-F1).
7.2. Welding inspector shall verify the electrode issue and verify the temperature of
baking/holding ovens on random basis.
7.3. Welders shall obtain welding consumables from Welding Foreman / Store Keeper, specific to
their jobs meeting the requirements of WPS. For coated electrodes only a quantity sufficient
to complete the weld or for a period of 8 hours whichever is less will be issue using
Electrode / Wire Issue Sheet
7.4. Unconsumed electrodes returned for storage are examined by the Welding Foremen / Store
Keeper for condition, cleanliness and identification before return to a segregated oven for
holding / re-baking if they have not been maintained in a portable oven. Only one re-baking
is permitted. Damaged or unidentified electrodes are scrapped.

8. MARKING OF ELECTRODES OR FLUX PACKAGE.

The following product information as a minimum shall be marked on the outside of each unit
package:

 AWS Specification and Classification designation

(year of issue may be excluded)
 Suppliers name and trade designation
 Size and net weight.
 Lot, control or heat number.

9. RECORDS

The following forms to be used for welding consumable Control:

 Welding Electrode Baking Record. (Form No. HCC-6-1-F2).

 Electrode/Wire issue sheet (Form No. HCC-6-1-F1).

10. Attachments

 Flow Chart for Control of SMAW Welding Electrode

 Attachment#1 of SAES-W-017
 Attachment#2 of SAES-W-017
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Consumables Rev. / Date : C / 28-05-2014

CONTROL OF SMAW WELDING ELECTRODES

ARRIVAL OF WELDING
CONSUMABLES

Verify batch number

Responsibility:- and Lot Number NO Notify
Store Keeper/QC with consumable Accordingly:
Inspector Certificates Quarantine
Consumables

Update the electrode RECORD

Responsibility:- register. Segregate
Store Keeper
Stock Record
consumables
.

Bake the low hydrogen Record Welding

electrode if not Electrode
Responsibility:-
purchased in hermetical Baking Record
Store
sealed container
Keeper/Welding
Forman

Transfer the electrode

Responsibility:- to holding oven after
Electrode Wire
Store baking and issue to site
Issue Record
Keeper/Welding upon requirement and
Forman update the register

Returned
Returned Electrode
Electrode Returned Electrode beyond
within
within permissible
permissible permissible exposure time
exposure time

Color Coding & Re

baking (only one time)

Holding Oven and

update the register
Document Responsibility: Welding Standards Committee SAES-W-017
Issue Date: 13 December 2011
Next Planned Update: 13 December 2016 Welding Requirements for API Tanks

Attachment I – Conditioning, Storage, and Exposure of SMAW Electrodes

(Notes 1, 2, 3)

Low Hydrogen Electrodes to A5.1

Drying and Re-drying

Prior to use all electrodes shall be dried at 260-430°C for 2 hours minimum.
The drying step may be deleted if the electrodes are supplied in the dried
condition in a hermetically sealed metal can with a positive indication of seal
integrity or vacuum sealed package. Electrodes may be re-dried only once.

Storage

After drying, the electrodes shall be stored continuously in ovens at 120°C

minimum.

Exposure

Upon removal from the drying or storage oven or hermetically sealed containers,
the electrodes may not be exposed to the atmosphere for more than 4 hours.
The exposure may be extended to 8 hours if the electrodes are continuously
stored in a portable electrode oven heated to 65°C minimum. Electrodes
exposed to the atmosphere for less than the permitted time period may be re-
conditioned. Electrodes exposed in excess of the permitted time period must be
re-dried. Electrodes that have become wet or moist shall not be used and shall
be discarded.

Re-conditioning

Electrodes exposed to the atmosphere for less than the permitted time period
may be returned to a holding oven maintained at 120°C minimum; after a
minimum holding period of four hours at 120°C minimum the electrodes may be
reissued.

Low Hydrogen Electrodes to A5.5

Drying and Re-drying

Prior to use all electrodes shall be dried at 370-430°C for 2 hours minimum.
For E70xx and E80xx electrodes, the drying step may be deleted if the
electrodes are supplied in the dried condition in a hermetically sealed metal can
with a positive indication of seal integrity or vacuum sealed package.
Electrodes may be re-dried only once.

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Document Responsibility: Welding Standards Committee SAES-W-017
Issue Date: 13 December 2011
Next Planned Update: 13 December 2016 Welding Requirements for API Tanks

Storage

After drying, the electrodes shall be stored continuously in ovens at 120°C

minimum.

Exposure

Upon removal from the drying or storage oven or hermetically sealed containers,
the electrodes may not be exposed to the atmosphere for more than 2 hours for
E70xx or E80xx electrodes and 30 minutes for any higher strength electrodes.
The exposure times may be doubled (to 4 hours and 1 hour, respectively) if the
electrodes are continuously stored in a portable electrode oven heated to 65°C
minimum. E70xx and E80xx electrodes exposed to the atmosphere for less than
the permitted time period may be re-conditioned. E70xx and E80xx electrodes
exposed in excess of the permitted time period must be re-dried. Higher
strength electrodes (above E80xx) must be re-dried after any atmospheric
exposure. Electrodes that have become wet or moist shall not be used and shall
be discarded.

Re-conditioning

E70xx and E80xx electrodes exposed to the atmosphere for less than the
permitted time period may be returned to a holding oven maintained at 120°C
minimum; after a minimum holding period of four hours at 120°C minimum the
electrodes may be reissued.

Stainless Steel and Non-Ferrous Electrodes

Drying and Re-drying

Prior to use all electrodes shall be dried at 120-250°C for 2 hours minimum.
The drying step may be deleted if the electrodes are supplied in the dried
condition in a hermetically sealed metal can with a positive indication of seal
integrity or vacuum sealed package. Electrodes may be re-dried only once.

Storage

After drying, the electrodes shall be stored continuously in ovens at 120-200°C

minimum.

Exposure

Upon removal from the drying or storage oven or hermetically sealed containers,
the electrodes may not be exposed to the atmosphere for more than 4 hours.
The exposure may be extended to 8 hours if the electrodes are continuously
stored in a portable electrode oven heated to 65°C minimum. Electrodes

Page 36 of 45
Document Responsibility: Welding Standards Committee SAES-W-017
Issue Date: 13 December 2011
Next Planned Update: 13 December 2016 Welding Requirements for API Tanks

exposed to the atmosphere for less than the permitted time period may be
re-conditioned. Electrodes exposed in excess of the permitted time period must
be re-dried. Electrodes that have become wet or moist shall not be used and
shall be discarded.

Re-conditioning

Electrodes exposed to the atmosphere for less than the permitted time period
may be returned to a holding oven maintained at 120°C minimum; after a
minimum holding period of four hours at 120°C minimum the electrodes may be
reissued.

Non-Low Hydrogen Electrodes to A5.1 or A5.5

The electrodes shall be stored in a dry environment. Any electrodes that have
become moist or wet shall not be used and shall be discarded.

Notes:

1) Storage and rebake ovens shall have a calibrated temperature gauge to

continuously monitor the temperature.

2) Portable electrode storage ovens with a minimum temperature of 120°C

are considered equivalent to storage ovens. Proper use of the oven
(e.g., closed lid, continuously on while in use) and periodic checks of the
temperature achieved with each portable oven are required.

3) Some applications may require higher drying temperatures and shorter

atmospheric exposure times.

4) Electrode types are listed in accordance with ASME SEC IIC.

Page 37 of 45
Document Responsibility: Welding Standards Committee SAES-W-017
Issue Date: 13 December 2011
Next Planned Update: 13 December 2016 Welding Requirements for API Tanks

Attachment II – Conditioning, Storage, and Exposure of Fluxes

SAW fluxes

Fluxes for material with a minimum specified tensile strength less than or equal
to 70Ksi

All fluxes shall be stored in sealed containers in a dry environment. Opened

SAW flux containers shall be stored continuously in ovens at 65°C minimum or
the manufacturer's recommendation, whichever is greater. Any flux that has
become moist or wet shall not be used and shall be discarded.

Fluxes for material with a minimum specified tensile strength exceeding 70 Ksi

Fluxes will be dried, stored and handled in accordance with the manufacturer’s
recommendations in order to achieve a dissolved hydrogen content of less than
8 ml H2/100 g metal. A written procedure giving the handling requirements will
be submitted to inspection.

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