Sub-Contractor Comments Response Sheet: Ain Tsila Development
Sub-Contractor Comments Response Sheet: Ain Tsila Development
Sub-Contractor Comments Response Sheet: Ain Tsila Development
PIUL Position
Sl. No. Document No. Rev PIUL COMMENT SUB-CONTRACTOR RESPONSE
( Open or Closed )
B-QAC-PRO-210-39156_B
A-CNT-CON-000-00282
Sub-contractor Name:
CODE DEFINITION
Revision History
Revision Changes
Holds
Hold No. Location Description
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CONTROL OF WELDING CONSUMABLE PROCEDURE
Document No: B-QAC-PRO-210-39156
Revision B
CONTENTS
REVISION HISTORY 2
CONTENTS 3
ABBREVIATIONS 4
1 INTRODUCTION 5
2 PURPOSE 5
3 SCOPE OF DOCUMENT 5
4 DEFINITIONS 5
5 REFERENCES 6
5.1 PROJECT SPECIFICATIONS 7
5.2 Codes 7
5.2.1 Algerian Codes and Standards: 7
5.2.2 International Codes and Standards: 8
6 RESPONSIBILITIES 8
6.1 Welding Engineer 8
6.2 Welding Consumable Store man 9
6.3 Welding Foreman 9
6.4 Welding Inspector 9
7. PROCEDURE 9
7.1 Approval of welding consumables 9
7.2 Packaging of low hydrogen SMAW electrodes 9
7.3 Purchase of Consumables 10
7.4 Receipt of Bulk Storage of Consumables 10
7.5 Identification & Color coding of welding consumables 10
7.6 Storage of Welding Consumables 11
7.7 Issue to Site Consumable store 11
7.8 Site Consumable Store 11
7.9 Thermal Treatment of Consumables 11
7.10 Issue of Welding Consumables 13
7.11 SMAW Electrodes (Standard Packaging) 13
7.12 SMAW Electrodes Vacuum Packaged 13
7.13 Inspection and Test Status 14
7.14 Test and Measuring Equipment 14
7.15 Safety 14
7.16 Training and Awareness program: 14
8 APPENDICES 15
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Abbreviations
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1. INTRODUCTION:
SARPI hereinafter referred as Subcontractor will execute the (Gathering Pipelines, Wellheads
& Manifolds MEI Works) Subcontract on behalf of PETROFAC referred hereafter as
Contractor.
2. PURPOSE:
The purpose of this procedure is to describe method of Controlling Welding Consumables
for permanent project work in AinTsila Development Project.
3. SCOPE OF DOCUMENT:
Scope of this Procedure Covers Welding Consumable materials on AinTsila Development
Project. This procedure contains:
• Process of purchase
• Process Storage
• Color Coding for identification
• Process of thermal treatment
• Process of managing issuing to and receipt from construction.
4. DEFINITIONS:
The terms and definitions as used within this document are listed below.
“COMPANY” or “GIS” means Groupement ISARÈNE (the operator of the Ain Tsila
Development)
“CONTRACTOR” or “PIUL” Petrofac International UAE Limited, who is in charge for the
execution of EPC project.
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UG Under Ground
AG Above Ground
MAR Material Approval Request
AFC Approved for Construction
CRA Corrosion Resistant Alloy
“shall” or “must” indicates that the specified action is mandatory (i.e. must be done by
the specified action party)
5. REFERENCES:
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5.2 Codes:
Current editions of the industry standards including all mandatory addenda in effect at the time
of the order shall apply unless otherwise indicated.
Algerian Gas Pipeline Regles de Security pour les Canalisations de Transport De gas
Regulations Combustibles (Safety Regulations for theTransport by Pipeline of
Combustible Gas)
Algerian Liquid Regles de Securite pour les Canalisations de Transport D’Hydrocarbures
Hydrocarbon Liquides (Safety Regulations for the Transport by Pipeline of Liquid
Pipeline Regulations Hydrocarbons)
Algerian LPG Pipeline Regles de Securite pour les Canalisations de Transport D’Hydrocarbures
Regulations Liquides liquefies sous pression (Safety Regulations for the Transport by
Pipeline of Hydrocarbons Liquefied Under Pressure)
P-CTE-1 Procédure de traitement des dossiers techniques et modalités d'exécution
des contrôles et essais règlementaires.
Note: French and English side-by-side translation
issued as project document A-PMT-PRO-000-00005.
Décret No. 88-35, 1988 Dédinissant la nature des canalisations et ouvrages annexes relatifs à la
production et au transport d’hydrocarbures ainsi que les procedures
applicables a leur réalisation
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6. RESPONSIBILITIES:
6.1 Welding Engineer
6.1.1 Reviews purchase requisitions to ensure correct consumables are purchased
against approved WPS and ensure Welding consumables certified to
EN10204-3.1 requirement.
6.1.2 Inspect in accordance with consumable batch certificates against purchase
requisition prior to release to stock. Assesses disposition where packaging
damage is observed
6.1.3 Establishes re-order levels to ensure there are no shortages during
construction.
6.1.4 Supervises welding audits by welding inspector, reviews audit records for
unacceptable trends.
6.1.5 Supervises consumable room personnel and operations.
6.1.6 Compiles welding consumable conditioning instructions.
6.1.7 Develops welding consumable color coding system.
6.1.8 Ensure batch numbers of consumables are recorded on consumable Thermal
treatment records. Ensure Consumable batch numbers are recorded during
inspection, issue and return of welding electrodes.
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7. PROCEDURE
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Low Alloy
Low Hydrogen E 8018-G Green
(Tie-in & Repair)
** Re-baked / returned electrodes shall be color coded as per Para 7.9.2 with
high temperature black color dye.
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7.5.3 For Electrodes Color code shall be applied on rear end of the electrode
across the electrode cross section.
7.5.4 Type of colors used shall be Sulphur, Zinc & Halogen free.
7.5.5 Color code Chart shall be stuck on walls of Stores and at various construction
notice boards for the easy identification of type of consumables.
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• All Low Hydrogen type basic coated welding electrodes shall be either
dried or baked as per the manufacturers’ recommendation and or specific
project instructions sheet which is based on manufacturers’
recommendation. The Welding Engineer shall establish thermal treatment
requirements based on the manufacturers recommendation and shall
supply thermal treatment instruction to the consumable Storekeeper
stating temp/time cycle for baking and holding ovens. Refer Para 7.9.3 for
required temperatures and durations.
• During weekends and public holidays, holding ovens are switched on and
temperatures are maintained as per manufacturer’s recommendations.
• Baking and holding ovens shall be uniquely numbered and the Welding
Inspector, using a calibrated digital thermometer, shall check
temperatures daily.
• During baking electrodes shall be stacked to permit adequate heat
distribution and avoid damage to the flux coating, maximum four layers.
Carbon Steels & CRA Welding Electrodes shall be baked in separate
ovens with the contents clearly marked on the door. Baking of electrodes
of the same type but different classification in the same oven shall be
avoided.
• Baking shall be the responsibility of the Storekeeper and baking activities
shall be logged on the Welding Consumable Treatment Log (Appendix
8.2)
• On completion of the baking cycle the electrodes shall be transferred to a
holding oven. Carbon Steels & CRA Welding Electrodes shall be held in
separate ovens with the contents clearly marked on the door. There shall
be no restriction for stacking in holding ovens. Holding of electrodes of the
same type but different classification in the same oven shall be avoided.
7.9.2 Re-baking of Low Hydrogen type SMAW Electrodes
• At the end of every shift the Welding Foreman shall ensure that any
unused electrodes are returned to the consumable store to an area
segregated for this purpose. Returned SMAW electrodes shall be re-
baked only once. On receiving returned electrodes, the Storekeeper shall
check the electrodes and discard those showing signs of coating damage.
He shall mark the end of the electrode for re-baking with high temperature
black dye prior to re-baking. Any returned electrodes marked with black
dye at the end shall be discarded and shall not be used for production
welding (These electrodes may be used for welder training).
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E 6010 &
Cellolosic Not applicable Not applicable
E 8010 P1
7.11.1 SMAW electrodes shall be issued from the holding oven into preheated
portable quivers, which shall maintain a temperature from 700C to 1000C.
The person shall receive the electrodes as per applicability of job and WPS
(Size and Quantity) from stores and this shall be recorded as per
Appendix 8.4.
7.11.2 Quiver temperature shall be monitored by the Welding Inspector on a daily
basis as part of daily welding surveillance. Portable quivers shall be
individually numbered.
7.11.3 Electrode issue quantity shall as a maximum be sufficient for one working
shift of up to 12 hours.
7.11.4 Quivers shall be returned to the consumable store at the end of every shift
and logged on the Quiver Control Sheet.
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7.14.1 Baking and holding ovens and potable heated quivers for use with SMAW
consumables shall be designed for that purpose. All items shall be checked
and calibrated periodically as per the manufacturers’ recommendations and
project requirements.
7.14.2 Baking ovens / Holding ovens / Quivers shall be calibrated as per
Management of monitoring and measuring procedure
(B-QAC-PRO-210-39164).
All calibration certificates shall be retained and filed in Quality Department
with a copy held in the consumable store and kept for future reference.
7.14.3 Temperature measuring devices on heating equipment above shall be
indicators only. Checks shall be by proprietary temperature sensitive crayon
or by calibrated digital thermometer on a regular basis when in use.
7.14.4 Measurement of atmospheric conditions shall be by the thermometer and
hygrometers.
7.15 Safety:
7.15.1 All operations shall be conducted in line with the requirements of Construction
Safety Procedures.
7.15.2 Necessary personnel safety equipment shall be provided and worn.
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8 APPENDICES
8.1 Flow Chart
8.2 Consumable Thermal Treatment Form
8.3 Consumable storage Surveillance Form
8.4 Consumable Request Card
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APPENDIX 8.1
APPENDIX 8.2
PROJECT: AINTSILA DEVELOPMENT PROJECT
RETURNED ELECTRODES
Name
Sign
Date
APPENDIX 8.3
PRJECT:
AINTSILA DEVELOPMENT PROJECT
DOCUMENT:
Consumable storage Surveillance
Form
NAME
POSITION
DATE
SIGNATURE
APPENDIX 8.4
INSPECTION & TEST RECORD-WELDING
ITR No: W-0101X
WELDING CONSUMABLES REQUEST CARD
JI2045-ITR-W-0101X Rev 0
W-0101X
Plant/Unit: Project No.: Record No.:
Drawing No.: Rev. No.: System/Sub-system No.:
Quiver: No…………………..……T(0C)………………………
Area: …………………………………………………………….
Issued by store
Shop No.: ……………………………………………………… Received by
keeper
Requested by Welding Foreman: Name: Name:
Name Signature Date Signature: Signature:
Date: Date:
Welder’s Name: ……………………………………………….. WELDING CONSUMABLES ISSUANCE
Welder’s ID: …………………………………………………….. Brand ǿ Issued
AWS No. Lot No.
WPS No. : …………………………… Name (mm) (kg.)
Quiver: No…………………..……T(0C)………………………
Area:
…………………………………………………………………….
Issued by store
Shop No.: ……………………………………………………… Received by
keeper
Requested by Welding Foreman: Name: Name:
Name Signature Date Signature: Signature:
Date: Date:
Name
Signature
Date