McDermott Arabia Company ttd (lK) Saudi Arabian Oil ComPanY (lK)

McDermott Middle East, Inc. (ooK) Aramco Overseas Company B.V. (SAUDI ARAMCO) (OOK)
Contract Nos. D6895 (lK) and D6255 (OOK) Contract Nos. 6500035804 (lK) and 660fi)35821 (OOK)

oromco

BI-10.00799 LTA FOR EPGI OF OFFSHORE FACILITIES .

GUARANTEED (LUMP SUM) SGOPE PROJECT

DOCUMENT TYPE: Procedure / Plan

DOCUMENT TITLE: WELDING CONSUMABLE STORAGE & HANDLING

DOCUMENT NUMBER: D6255/D6896-AOC-W-ENGG-003

-)
Itt*
tiW\-/ ^-l\t#/ &/ lnk
00a 16-May-2016 Approved
for Construction
SPS 0Ksv 4; ^v/
vpltt
Approved for /.ro SV PM
00 03-Apr-2016 PK
Construction
B l0-Mar-2016 Re-lssued For Approva JK JD SV PM
A 4-Mar-2016 lssued For Approval JK JD SV PM

Rev. Date Description Prepared Reviewed QA HSES Approved Glient

Project documents are controlled

doCuments. Revisions0aredenoted in
the right-hand margin.
 og
Offshore Projects Department I OOK Fabrication Division

Aramco Overseas ComPanY B.v' Tet: +971 {4) 801-a0ol

Grcund Ftoor, POB 1022 Client Buitding Fd: {971 (4) E83-1a50
Jebei Ati, Dubai - UAE

By
Gurmeet / Kumar, Jayaraman TRANSMITTAL

Aprit 3, 2016
ooKFD/T-1867116

MCDERMOfi MIDDLE EAST INC' OOK FABRICATION DIVISION' OPD

MMEI CLIENT OFFICE, JEBEL ALl, DUBAI
P.O. BOX 16961, JEBELALI, DUBAI
UNITED ARAB EMIMTES UNITED ARAB EMIRATES

LUMP SUM

Ref . : lilIrtEl/D625 5 (OOK)/DT033 52/ 1 6

Attached please find the followlng documents:

l-l tetter fl neports fl Envelope [lotners

f] Drawinss

WEUONTC .ONSUIIMBLES STORAGE & HANDLING REV. B

COMPANY has reviewed the subiect document and approved with fotlowing condition:

r Yard scope'
This approval is appticabl,e onty for McDermott Fabrlcation

Shoutd you have any questions, ptease contact Ahmed

A' At'shuwaier on +971 4 803 4045 or the
undersigned.

-
,&?
-r-ffinYRePresentative
FdY oox Fabrication
Division

with SAEP.'I27
KcelPt or rness surrrstrr> srr'5"r \"s
Y
--,.-
rL'"ri i.pv any portlon of thls document. lf you requlr
7IO.OO2 for proper handling of sensltlve documnts
addltlonal coplei, please conta4 the above Fc

pS us:sr A,
RECEIVED
cc: MA/HMS /l{.AS /AlS/MZA/MRU /Jl
0 3 APR 20t6
Flle 7 .5.4.2 (Contractors)
ffi-pv Pn$sED
0 I' APR ?0lE ffiu, :l tY
,teHil.l$.!lsls
 McDermott Arabia Company ttd (lK) Saudi Arabian Oil Company (lK)
McDermott Middle East, lnc. (OOKI Aramco overseas Company B.v (ooK) $f
Contract Nos. D6896 (lK) and D6255 (OOK) contract Nos'66000358"
"
Hle'ffi'i;' ffi

TABLE OF CONTENTS
a
0.0

1.0 L

2.0 A

E
3.0

4.0 a

5.0 1n

6.0

EXHIBIT-1 Welding Gonsumable oven Temperature Monitoring Card ............15

EXHIBIT-2 Charpy lmpact Transition Temperature Gurves (SMAW Consumables)...........................16

EXHIB|T-3 Gharpy lmpact Transition Temperature Curves (FCAW Consumables)...........................17

EXHIBIT4 Gharpy lmpact Transition Temperature Curves (SAW Consumables)........... 2t>

EXHIBIT-S Welding Consumable First In and First Out Record(ForWarehouse Only)......................19 r
{oo")
EXH|BIT-6 Welding Consumable First In and First Out Record(For Satellite Store)"....... ,V
( ooa

EXHf BfT-7 Welding Consumable lssuance Log (For Satellite Consumable Store).... .........21,2

(Additional Requirements For Control Of Exotic Welding Gonsumables)

(Preventive Action Plan For The Control Of Chevron Cracking)

(Oerlikon Gonsumable Back-up for Flux Baking Temperatures)

D6255/D6S96-AOC-W-ENGG-003 Rev.OOa- Welding consumable storage and Handling Page | 2

 McDermott Arabia Company ttd (lKl Saudi Arabian Oil Company (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas Company B.V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.5600035804 (lK) and 6600035821

oromco
1.0 Scope

1.1 This Welding Consumable Storage & handling Procedure is applicable for Onshore and Offshore
construction, Installation and Pre-commissioning phase of Offshore Platforms, Pipelines, and
cables.
1.2 This Welding Consumable Storage & handling Procedure is a "live" document and such will be
subjected to periodic reviews / changes in line with identified and agreed amendments and
improvements during the course of the Project. The Welding Consumable Storage & Handling
procedure will also be reviewed and updated to accommodate any addition or changes in scope
of work.
1.3 A flow chart illustrating the basic steps of the procedure is provided in Section 0.0, which may be
posted in the work area as a work instruction.

1.4
.t
The internal Supplier-Customer Relationship is illustrated below.

Warehouse r
Electrode | | Consumable\ JleoetAliYard(welding
Manufacturer f + Handlins& i tr+
\ Storage 1
Welding | \ / ponsumable Store &
Engineer Satellite welding Consumable
) I
Supplier Work Process Customer

2.0 Reference

2.1 AWS D1.1 - StructuralWelding Code.

2.2 API 1104 - Welding of Pipelines and Related Facilities.
2.3 ASME 831 - ASME/ANSI Code for Pressure Piping.
2.4 DNV - Rules for Submarine Pipelines
2.5 ASME Sec Vlll - Boiler & Pressure Vessels Code - Rules for Construction of Pressure
Vessels
2.6 BS 6693, Part 1 - Method for Determination of Hydrogen in Manual Metal-Arc Weld Metal
2.7 ASME Sec ll Part C - Boiler and Pressure Vessels Code - Specifications for Welding
Rods, Electrodes and Filler Metals
2.8 EEMUA 158 - Construction specification for fixed offshore structures in the north sea

2.9 ASME SEC. lX - Boiler & Pressure Vessel Code - Welding & Brazing Qualifications.
2.10 SAES-W-O10: Welding requirements for Pressure Vessel
2.11 SAES-W-011: Welding requirements for On-Plot Piping

2.12 SAES-W-012: Welding requirements for Pipelines

2.13 SAES-W-O13: Welding requirements for Offshore Structures

214 SAES-W-O14: Weld Overlays and Welding of clad materials

2.15 SAES-W-019:Girth Welding requirement for Clad Pipes

216 DE-1 19896: Procedure for Welding

2.17 DE- 1 19951: procedure for Monel sheathing Installation

D6255/D6896-AOC-W-ENGG-003 Rev.00a- Welding consumable storage and Handling Page | 4

 McDermott Arabia Company ttd (lK) Saudi Arabian Oil Company (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B.V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.6500035804 (lK) and 5600035821

oromco

3.0 Definitions

3.1 Extra Low Hydrogen Electrodes - are semi-iron powder low hydrogen type which produce deposits
that are extremely low in hydrogen content having a maximum weld metal diffusible hydrogen content of
< 5 ml/1009.

3.2 Transition Temperature Gurve - a curve which denotes the arbitrarily defined temperature within the
temperature range in which the metal fracture characteristics or ductility determined usually by notched
tests are changing rapidly with temperature.

4.0 Procedure

4.1 Responsibility of Personnel

4.1.1 The Warehouse Supervisor bears ultimate responsibility for the storage and handling of
electrodes within the Warehouse. He shall assure that the electrodes are stored and handled
as prescribed in section 4.2.7 of this procedure immediately upon accepting receipt of
electrode consumables. He shall also ensure that test certificates for all batches & verify the B.
No. on received boxes. In case, B. No. on some boxes are not visible on any pallet, he shall
arrange to open pallet to verify all the boxes. He shall file certificate in hard, as well as soft
copy form, so as to have easy retrievability.

4.1.2 The Welding Supervisor bears ultimate responsibility for storage and handling of electrodes
within his control. He shall assure that the electrodes are stored and handled as prescribed in
section 4.2.1 to 4.2.6 of this procedure immediately upon receipt of issued electrodes
consumables from warehouse. Satellite electrode storage containers shall be maintained by
the area Supervisor.

4.1.3 Welding consumable store keeper shall be trained to handle their responsibility and shall have
clear understanding of the requirements specified by this document. Records of this training
shall be maintained by welding supervisor.

4.1.4 Refer to Appendix 1 for the control of exotic welding consumables.

4.2 Storage & Handling

4.2.1 Baking and holding ovens shall be in good working condition and with a calibrated
temperature gauge. Ovens may be color coded as per the color code table in Appendix 1.0

4.2.2 Low Hydrogen (Basic) Covered Electrodes

4.2.2.1Welding materials shall be stored and properly arranged in a dry storage

area, free from inclement weather and contaminants. The storage area
designated for electrode consumables shall be designated only for electrode
consumables.

4.2.2.2 Low Hydrogen type covered welding electrodes that are received in
hermetically sealed containers, may upon opening of the containers be used
immediately. Electrodes that will not be used immediately shall be put into a
Holding Oven for an indefinite period of time, at a minimum temperature of
250oF (121oC). Discard or re-dry the electrodes which are exposed to
atmosphere more than the permitted exposure limit.

4.2.2.3 Low Hydrogen type covered electrodes that are not received in hermetically
sealed containers shall be dried for at least two hours in a Baking Oven, held
at a minimum temperature of 572oF (300oC). Electrodes that have been
D6255/D6896-AOC-W-ENGG-003 Rev.00a- Welding consumable storage and Handling Page | 5
 McDermott Arabia Company ttd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B.V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.6600035804 (lK) and 5600035821

oromco
baked for a minimum of two (2) hours shall be transferred to the Holding
Oven. Carbon steel electrodes of different grades (e.g. E 7016, E 7018, etc)
may be baked / stored in the same oven with proper identification, in
separate tray and with proper segregation.

4.2.2.4 Low Hydrogen type covered electrodes shall be issued only from a recently
opened container or from the Holding Oven. Electrodes are issued only in a
quantity sufficient to complete the weld or for a four (4) hour period,
whichever is less.

i) The four (4) hour exposure limit may be extended to eight (8)
hours by storing rods into a portable rod quiver heated to
158oF (70oC) at each welding location.
ii)Anye|ectrodesexceedingtheexposurelimitssha|lbe
discarded or baked for a maximum of two (2) hours at 300"C
and returned to the Holding Oven.

iii) When renewing electrode stocks in the Baking/Holding Oven

they shall be stacked and trayed to facilitate issuance on
'first-in' 'first-out basis (For Satellite Store- Exhibit -6).

iv) Electrodes unused at the end of the exposure period

specified in i) shall be returned to the Holding Oven'

v) Electrodes of different grades (e.9. E7018-1 & E7016-1) shall

not be kept in the portable holding oven at any point of time.

4.2.2.5 Satellite storage areas shall be properly identified and maintained in

good order. Open containers shall not be left remaining and are to
have their contents baked as per paragraph 4.2.1 above.

4.2.2.6 Electrode Ovens shall be properly identified and used onlv for
electrodes. The area Supervisor shall check to assure these Ovens
remain in working conditions and used properly, as intended by this
procedure.

4.2.3 lron Oxide Electrodes, Rutile Type Electrodes & Cellulose Electrodes.

4.2.3.1 Non-Low Hydrogen covered electrodes shall be kept in a dry

(Temperature 150oF) and dust free enclosure even after opening of
<
the factory container.

4.2.3.2 Non-Low Hydrogen covered electrodes shall be issued in undamaged

condition.

i) Sufficient quantity shall be issued to complete the weld or for

a maximum quanti$ Per shift.

ii) Electrodes unused at the end of the shift (maximum

exposure period) shall be returned to their proper storage
location as identified in 4.2.3.1.

D6255/D6895-AOC-W-ENGG-OO3 Rev.OOa- Welding consumable storage and Handling Page I 6

 McDermott Arabia Company ttd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B.V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.6600035804 (lK) and 6600035821

oromco
4.2.3.3 These nonlow Hydrogen electrodes shall not be held at an Oven
temperature above 150oF (66oC) as the coatings and weldability of the
electrodes may be imPaired.

4.2.3.4 Should any of these electrodes have become wet, or contaminated or

damaged they shallthen be discarded.

4.2.4 Submerged Arc Welding Fluxes (Metal)

4.2.4.1 Fluxes shall be stored in a dry storage area. Opened containers shall
be stored in heated flux oven/silos.

4.2.4.2 Flux containers or bags shall be issued unopened or unpunctured.

i) Sufficient quantity shall be issued / transferred to flux holding /

baking oven to complete the weld or for a maximum quantity
require Per shift.

ii) Unconsumed flux shall be returned to the heated flux

oven/silos at the end of each shift or discarded'

iii) Flux exposed to storage temp. range 1540'C & / or

RH >
60% shall undergo redrying for 2 hrs for ESAB OK 10'71 and
OK 10.62 consumables and 4 hours for Oerlikon OP121Tf
flux at 230-300'C. Flux may be used directly from hermetically
sealed bags provided due precautions as prescribed in
Appendix 2 are addressed.

4.2.4.9 The heated flux ovenisilo is kept at a minimum holding temperature of

t t
150 25"C (302 77"F). Any unconsumed flux that is immediately
recovered and filtered is permissible for continued re-use, provided
new flux is added at approximate half mix. To prevent from chevron
cracks of long seam welds, APPENDIX -2 shall be followed (preventive
action plan for control of chevron cracks).

4.2.4.4 Flux baking Ovens shall be cleady identified for a particular type/brand
of flux. The drea Supervisor shall check to assure these Ovens remain
in working conditions and used properly, as intended by this
procedure.

i) Wet / damp Flux shall be subjected to re-drying at 300"C for

2Hrs or shall be discarded.

Note :- Handling for Welding Consumables (SAW-welding Flux)

i) Before taking the flux from the Baking / Holding oven, each
welder /welding operator shall take out at least 2 or more
pails of fluxes from the oven and put them back into the oven
from the top; to ensure that welding flux issued is sufficiently
hot, temp should be at least above 125"C (257"F).

Before issuing /transferring flux from flux oven to the flux

hopper for production welding, each welder/welding operator
shall aware that the properly heated, if otherwise fluxes
D6255/D6S96-AOC-W-ENGG-003 Rev.00a- Welding consumable storage and Handling Page | 7
 McDermott Arabia Company ttd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (ooK) Aramco Overseas ComPanY B.V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.660003580a (lK) and 6500035821

oromco
shall be heated / dried as stated above.

ii i) Any break during welding e.g. Lunch break, shift change, or

any other fabrication sequences, flux from the hopper shall
be replaced with hot flux from the oven. This shall be
applicable to both types of flux hoppers with or without
heating arrangement.

iv) ln back welding stations, wherein "Heating type Flux

Hopper" is not available, in no occasion any flux shall be
used for welding which has been kept for more that 1
hour prior to welding. The flux shall be replaced with the
fresh flux from the holding oven.

4.2.5 Bare Wire Electrode (solid and flux cored)

4.2.5.1 Bare wire electrodes shall be stored in original cartons and in a dry
storage area off the floor, until issued.

4.2.5.2 Bare wire in opened bags must be resealed.

i) Bare wire electrode shall be issued in sufficient quantity to

complete the weld or for a maximum quantity per shift.

ii) Unused bare wire shall be returned to storage or remain in a

sealed condition.

4.2.6 Bare Wire Electrode (solid and flux cored)

4.2.6.1 Storage and Handling of consumables at Shop stores and Satellite

containers:

The Welding consumables shall be stored under controlled

temperature and humidity conditions. These conditions are defined as
follows

(Storage temperature 15 to 40'C - relative humidity shall be 60% max)

(lf RH% of exceeds the maximum limit of 60%, any welding

consumables exposed to this condition, or found wet / damp, shall
undergo redrying at baking oven (as per 4.2.1 for SMAW & 4.2.41or
SAW) before issuing the same forwelding.)

The above does not apply to vacuum packed electrodes / hermetically

sealed consumables. The welding supervisor shall ensure that the
vacuum packing / hermatic sealare intact.

4.2.7 Storage and Handling of consumables in warehouse:

The welding materials including, but not limited to, low hydrogen (basic coated)
electrodes, iron oxide electrodes, rutile electrodes, cellulosic electrodes, SAW
Fluxes and bare wire electrodes (solid and flux cored) shall be stored in
warehouse with the packing intact. The welding materials shall be stored and
D6255/D6896-AOC-W-ENGG-OO3 Rev. Ooa- Welding consumable storage and Handling Page | 8
 McDermott Arabia CompanY ttd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (ooK) Aramco Overseas ComPanY B'V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.6500035804 (lK) and 6500035821

oromco
properly arranged in designated areas, free from inclement weather and
contaminates. The consumable from Warehouse shall be issued First- In & first-
Out basis. (Exhibit-5- For Warehouse )

4.3 Monitoring

4.3.1 The area Supervisor, Welding Foreman shall monitor the storage and handling of
the welding consumables. QC inspector will verify for the same during spot
inspection & during consumable audits / welding audits for its compliance.

4.3.1.1 Periodic checks shall be made by the individuals to assure compliance

to this procedure.

4.3.1.2 Storage areas shall be designated only for electrode consumables.

These areas shall be free of contaminates or from any other intended
purposes other than electrode consumable storage.

4.3.1.3 Ovens where located shall be identified as either a Holding Oven,

Baking oven or Flux oven with the minimum specified temperature
posted. These ovens shall be checked to assure that they are in
proper working condition and suited for their intended purpose'

4.3.1.4 House-keeping of the storage area shall be maintained by the Area

supervisor under the direction of the welding superintendent. Empty
containers and allother packing debris shall be removed.

4.g.1.5 Welding consumables specifically identified for a project may be stored

with welding consumables of another project consumables within the
same satellite container on site, provided the storing area are
segregated and clearly identified to the satisfaction of welding foreman
/ QC inspector and shall only be used for that specific project. lf any
specific tested loUsingle lot requirement is there in a particular project,
the consumable shall be clearly identified and allocated / be issued
under proPer control method.

4.3.1.6 Welding consumables returned from offshore/other projects shall be

forwarded to warehouse through RTS by the concerned field engineer
/ PMT engineer / welding supervisor. In case of insufficient
documentation (RTS, UID) or details, the consumables received.
shall be kept under Quarantine tillthe details are available for review.
Upon receipt of all details / information the consumables to be
handled in acc. with this procedure & D6255/D6896-AOC-MATL-003.

4.3.2 All monitoring checks made by the individual designated in 4.3.1 of this
procedure, shall record the date and their initials upon posted monitoring cards
(Exhibit 1) located in each area to signify compliance, any non-compliance shall
be dealt with immediately and condition rectified by the individual.

D6255/D6896-AOC-W-ENGG-003 Rev.00a- Welding consumable storage and Handling Page | 9

 McDermott Arabia company Ltd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B.V
Contract Nos. D6896 (lK) and D5255 (OOK) Contract Nos.6600035804 (lK) and 6500035821

oromco
5.0 Documentation

5.1 SMAW Electrodes List Data Sheet

AWS Trade Name Manuf. Recommendation Diffusible Transition
or storaqe Hvdrooen Limit Temoerature
E7018 Lincoln LH70 < 4ML /1009 Refer to Exhibit 2
a) Unopened container keeP in a
dry storage area.
b) Opened container 250oF-300oF
(120-150oC)
c) Re-drying at 300oF (340-400oC)
for t hour. (Max. 3 cycles)
E7016-1 ETC PH 565 Same as Above Refer to Exhibit 2
E7016-1 TENAX 565 Same as Above Refer to Exhibit 2
E7016-1 ESAB OK 53.68 Same as Above Refer to Exhibit 2
E7016-1 ESAB FILARC 565 Same as Above Refer to Exhibit 2
E8018G PHILIPS 27P Same as Above < 5MU100q lefer to Exhibit 2
E8018 Lincoln Same as Above < 4 MU100g Refer to Exhibit 2
JetLH8O18-C1 MR
E7018 Mediocarb 7018 Re-drying @ 280-300"C lor 2 Hours 4.8M1/1009 to NA
7.3M1/100q
E7018-1 ESAB OK 55.00 a) Unopened container keeP NA
in a dry storage area
b) Opened container 250oF
-300oF (120-150oc)
c) Redrying at 662oF (350"C)
for 2 hour. (Max. 3 cycles)

E7018 ESAB OK 48.00 Re-drvinq temp @ 350"C for 2 hours < 5MU100s NA
E7018 ESAB OK 48.08 Re-drvino temo @ 350"C for 2 hours < 5MU100q NA
> 50ML/1009 NA
E6010 -incoln Fleet- weld 5P Store in sealed containers. KeeP
in dust free supply room after
opening factory container. Do not
place in holding ovens above
1sooF (66oC).

E8010-G Lincoln Shield Arc Same as above > 50 MU100g Refer to Exhibit 2
70+
E7010-G Lincoln Shield Same as above > 50 MU100g Refer to Exhibit 2
Arc HYP
E6027 ESAB OK Femax Same as above > 20 MU100g NA
39.50
E7O2B HYUNDAIS-7028-F Dry electrodes @ 350400"C NA
for t
hour
E8018 Cl LINCOLN Redrying @370 -430"Cfor t hour < 4 MU100g NA
JET-LH8O18C1MR
E8018 C1-H4 LINCOLN KRYO-3 Redrying @ 280-300"C for 2 hours < 4 MU100g NA

E7010-Pl HOBART Store in sealed containers, Dry > 50 MU100g NA

PIPEMASTER 70 @ room temperature,
Reconditioning : Not recommended

D625S/D6S96-AOC-W-ENGG-003 Rev.00a- Welding consumable storage and Handling Page | L0

 McDermott Arabia Company ttd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B.V
Contract Nos. D6895 (lK) and D6255 (OOK) Contract Nos.5600035804 (lK) and 6600035821

oromco
AWS Trade Name Manuf. Recommendation Diffusible Transition
or Storaqe Hvdroqen Limit Temperature

E7010-P1 HOBART Store in sealed containers, > 50 MU100g NA

PIPEMASTER 70 Dry @ room temperature,
Reconditioninq : Not recommended
E8010-P1 HOBART Store in sealed containers, > 50 MU100g NA
PIPEMASTER 80 Dry @ room temperature,
Reconditioninq: Not recommended
E7010-P1 THYSSEN CEL.75 Same as above > 50 MU100q NA
E8018-C3 LINCOLN Open Cans stored in a cabinet < 4 MU100g NA
EXCALIBUR @ 120-150"C should be given
8018 C3 MR no more than three
1-hour re-dries in the 370-430'C
range.

E3091-1 5 ESAB OK 67.75 Redrvinq Temp @ 200 "C for 2 Hrs. < 15 MU100q NA
E3091-16 ESAB OK 67.66 Redryinq Temp @ 250'C for 2 Hrs. < 15 MU100q NA
E3161-17 ESAB OK 63.30 Redrvinq Temp @ 350 "C for 2 Hrs < 15 MU100q NA
E3161-1 7 ESAB OK 67.60 Stored in sealed containers < 15 MU100g NA
Redryinq temp @ 350"C for 2 hours
E2209-17 ESAB OK 67.50 Same as Above Same as Above NA
EBo18-Cl ESAB OK 73,68 Same as Above Same as Above NA
E7018G OERLIKON a) Stored in sealed container < 5 MU100g Refer to Exhibit 2
b) After 4 hrs. exposure to
work bake at 300-350oC for 2 hrs.
c) Maximum holding time at 150oC
after baking: 1 week.

ENiCrMo-3 INCONEL 112 a) Stored in sealed container NA

b) Baked @ 260"C for 2 hours if
electrodes have absorbed
excessive moisture.
c)Opened containers of electrodes
must be dried at 100-120'C
before use.

ECuNi Monel 187 Stored in sealed container. NA

5.2 FGAW Electrodes List Data Sheet

AWS Trade Name Manuf. Recommendation Diffusible Transition

or Storaqe Hvdroqen Limit TemDerature

E61T8-K6 Lincoln Inner shield Maintain in dry storage condition < 15ML/1009 Refer to Exhibit 3
Self Shielded) NR203 Ni C
E71TB-Ni1 Lincoln lnner shield Same as Above < 15ML/1009 Refer to Exhibit 3
Self Shielded) NR203Ni1
E61T-8 Lincoln Inner shield Same as Above < 15ML/1009 NA
Self Shielded) NR 204
E71T-Gs Lincoln NR 205 Same as Above < 15ML/1009 NA
[Self Shielded)

D6255/D6896-AOC-W-ENGG-003 Rev.00a- Welding consumable storage and Handling Page | 11

 McDermott Arabia Company ttd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B.V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.5600035804 (lK) and 6600035821

oromco
AWS Trade Name Manuf. Recommendation Diffusible Transition
or Storaqe Hvdroqen Limit Temperature

E71T8-K6 Lincoln NR 207 Same as Above < 15ML/1009 Refer to Exhibit 3

Self Shielded)
E71T8-K6 Hobart Fabshield Same as Above < 8MU100g Refer to Exhibit 3
71 K6
E71T-1 Lincoln Outer shield Same as Above < 8MU100g Refer to Exhibit 3
Gas Shielded) 71
E71r-1 ESAB OK TUBROD Same as Above s 8MU100g NA
15.15
E81T-1 Ni1 Lincoln Outer shield Same as Above < 8MU100g NA
Gas Shielded) 81-Ni1H
E81T-1 Ni2 WB Alloys Same as Above < 8MU100g NA
Gas Shielded) wB 61215C
E81T-8 Ni2 Lincoln lnner shield Same as Above < 8MU100g NA
lGas Shielded) NR55O-H
< 3.5 MU100g NA
E81T1-G {ST -
Nittetsu Same as Above
Gas Shielded) JF.3AM
E71T-1C ST SF-1E Same as Above < 3 MU100q NA
E71T-1 I Same as Above < 3 MU100g NA
NST - MC-1
E 70C-6M
Gas Shielded)
< 3 MU100g NA
E SOCN| MH4 NST - MC- RS Same as Above
Gas Shielded)
E71T-1CJH4 ESAB OK TUBROD Same as Above < 4MU100g NA
15.13C

5.3 SAW Electrodes List Data Sheet

AWS Trade Name Manuf. Recommendation Diffusible Transition

or Storaqe Hvdrooen Limit Temperature

EM12KF7P2 ESAB AUTROD Maintain in dry storage area < 4MU100g Refer to Exhibit 4
12.22t10.71
EH12K ESAB OK AUTROD Same as above < 4MU100g Refer to Exhibit 4
12.32
EH12KJF7A8 OERLIKON OE-SD3 Same as above < 4MU100o NA
ENi5/F746 Lincoln LNS165/850( Same as above < 8MU100q NA
< 8MU100g WELTIG Cu 90 Stored in a sealed container & NA NA
maintain in a drv storaqe area
ERCuNi MONEL 67 Same as above NA NA

D6255/D5S96-AOC-W-ENGG-003 Rev. 00a- Welding consumable storage and Handling Page I L2

 McDermott Arabia Company ttd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas CompanY B'V
Contract Nos. D5896 (lK) and D5255 (OOK) Contract Nos.6600035804 (1K) and 5600035821 (OOK

oromco
5.4 SAW Flux List Data Sheet

AWS Trade Name Manuf. Recommendation Diffusible Transition

or Storaqe Hvdroqen Limit Temoerature

F7M Lincoln 860 a) Un-opened container KeeP N/A NA

in a dry storage area
b) Redrying at (300-375'C) for
1-2hr hour if exposed for
several days.
c) Redried flux and flux handled for
welding at a temp. of 50-120oC min

F7P2 Lincoln 865 Same as above NA NA

F7A6 Lincoln 8500 Same as above <5ML/100q NA
F7A8 ESAB OK Flux 10.62 Same as above <5ML/100q NA
F7P2 ESAB OK Flux 10.71 a) Unopened container KeeP in a 4-7 MU100g NA
Dry storage area
b) Unopened flux bags should not
be exposed to direct moisture such
as rain or snow.
c) Remaining flux from oPen bags
or flux hoppers must be kePt at
a temperature of 150+/-25"C.
d) lf the Fluxes have become wet,
the flux shall be re-baked at
300+/-25'C

F7A8 OERLIKON OP121T- a) Maintained in controlled dry 4-7 ML/1009 NA

condition at a minimum temp. of
lBoC and a relative humiditY not
exceeding 60% RH.
b) Opened bags or drums
Maintained at a temp. of 100oC
minimum.
c) Exposure to workshoP condition
limited to a maximum of 10 hrs.
d) When it is necessary to rebake,
i.e., flux left exposed in excess
of 10 hrs., exposed flux should
be rebaked at 300oC-350oC for
two hours.
e) When it is necessary to re-bake
(when shop ovens do reach 300
"C), i.e., flux lefi exposed in
excess of 10 hrs., exPosed flux
should be re-baked at
275oC-290oC for four hours
N/A INCOFLUX 7 :lux is recommended to be re-dried NA NA
lt 300-350'C for 2 hours prior to use
N/A MARATHON 444 rlux is recommended to be re-dried NA NA
lt 300-350"C for 2 hours prior to use

D625S/D6896-AOC-W-ENGG-OO3 Rev.00a- Welding consumable storage and Handling Page | 13

 McDermott Arabia Company Ltd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B.V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.6600035804 (lK! and 6500035821

oromco
5.5 GTAW Filler Metal List Data Sheet

AWS Trade Name Manuf. Recommendation Diffusible Transition

or Storaqe Hvdroqen Limit Temperature

ERNiCuT Huntinqton Monel60Maintain in dry storage area < 5MU100q NA

ERNi-1 Huntinqton Nickel6l
Same as above NA NA
ER3O9 ESAB TIG Rod 16.5iSame as above NA NA
ER316L ESAB TIG Rod 16.3(Same as above NA NA
ERTOS-2 ESAB TIG Rod 12.62Same as above NA NA
ER705.6 ESAB TIG Rod 12.62Same as above NA NA
ERSOS-NI1 )ERLIKON Carborod Same as above NA NA
NA 30HLER CN22/9N-1( Same as above NA NA
NA SAB OK 13.27 Same as above NA NA
NA SAB OK 16.86 Same as above NA NA
NA ]OHLER 2.5 Ni-1G Same as above NA NA
ERNiCTMo-3 NCONEL 625 itored in sealed container and NA NA
naintain in a drv storaqe area
ERCUNi A/ELTIG Cu90 Same as above NA NA
ERCuNi UIONEL 67 Same as above NA NA

5.6 GMAW List Data Sheet

AWS Trade Name Manuf. Recommendation Diffusible Transition

or storaqe Hvdroaen Limit Temperature

E70S-2 Linde 65 Maintain in dry storaqe area <8ML/100q NA

E70S-2 :SAB AUTROD 12.62 Maintain in drv storaqe area <5ML/100q NA
E3161 SAB AUTROD 16.32 Maintain in dry storaqe area <5ML/100q NA
E7O56 IERLIKON Carbofil 1 Stored at a minimum temPerature NA NA
of 18oC and a maximum relative
humiditv of 60% RH.
E70S-6 :SAB AUTROD 12.51 Maintain in dry storaqe area NA NA
ER 705-6 LINCOLN MD-SG2 Maintain in drv storaqe area NA NA

6.0 HSES

All Personnel involved in Welding Consumable storage and handling shall follow the requirements and Policy
of McDermott HSES.

D6255/D6896-AOC-W-ENGG-003 Rev.00a- Welding consumable storage and Handling Page | 14

 McDermott Arabia Company ttd (lK) Saudi Arabian Oil Company (lK)
McDermott Middte East, Inc. (OOK) Aramco Overseas Company B.V
Contract Nos. D6896 (tK) and D5255 (OOK) Contract Nos.6600035804 (lK) and 5600035821

oromco
EXHIBIT 1

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D6255/D6896-AOC-W-ENGG-003 Rev. 00a- Welding consumable storage and Handling Page | 1'5
 McDermott Arabia Company ttd (lK) Saudi Arabian Oil Company (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B'V
Contract Nos. D6896 (lKl and D6255 (OOK) Contract Nos.6600035804 (!K) and 6600035821

oromco
EXHIBIT 2

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D6255/D6896-AOC-W-ENGG-003 Rev. 00a- Welding consumable storaBe and Handling Page | 15

 McDermott Arabia Company Ltd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B'V
Contract Nos. D5896 (lK) and D6255 (OOK) Contract Nos.6500035804 (lKl and 5600035821

oromco
EXHIBIT 3

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D6255/D6896-AOC-W-ENGG-003 Rev. 00a- Welding consumable storage and Handling Page I t7

 McDermott Arabia Company ttd (lK) Saudi Arabian Oil Company (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas Company B.V
Contract Nos. D6896 (lK) and D6255 (OOKI Contract Nos.660d)35804 (lKl and 6600035821

oromco
EXHIBIT 4

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D6255/D6S96-AOC-W-ENGG-003 Rev.00a- Welding consumable storage and Handling Page | 18

 McDermott Arabia Company ttd (lK) Saudi Arabian Oil Company (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas Company B.V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.6600035804 (lK) and 6600035821

oromco
EXHIBIT 5 (ForWarehouse onlv)

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D6255/D6896-AOC-W-ENGG-OO3 Rev.00a- Welding consumable storage and Handling Page | 19

 McDermott Arabia Company ttd (lK) Saudi Arabian Oil Company (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas Company B'V
Contract Nos. D6895 (tK) and D6255 (OOK) Contract Nos.650003580a (lK) and 6600035821

oromco
EXHIBIT 6 (For Satellite Store)

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D6255/D6896-AOC-W-ENGG-003 Rev. 00a- Welding consumable storage and Handling Page | 20

 McDermott Arabia ComPanY ttd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, ]nc. (OOK) Aramco Overseas ComPanY B'V
Contract Nos.6500035804 (lK) and 6600035821
Contract Nos. D6896 (lK) and D5255 (OOK)

oromco:

EXHIBIT 7 (For Satellite Store)

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D6255/D6896-AOC-W-ENGG-003 Rev. 00a- Welding consumable storage and Handling Page | 21

 McDermott Arabia company ttd (lK) saudi Arabian oil company (lK|
McDermott Middle East, Inc. (OOK) Aramco Overseas Company B'V
Contract Nos. D6896 (tK) and D5255 (OOK) Contract Nos.66fi)035804 (lK) and 6600035821

oromco
APPENDIX 1 . ADDITIONAL REQUIREMENTS FOR THE CONTROL OF EXOTIC WELDING
CONSUMABLES

MDR-ME-L2-WT-005-APPI (Click this link complete document)

ncv. t/ D TtD: tlrn y,1009

J. RAY |*cDERiIOTT

PREVENTIVE ACTION PLAN

FOR THE CONTROL OF

EXOTIC WELDING CONSUI,IABLES

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l' *iv r'Lornr'rorr
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J. RAy ildtenrAotr "" RAY
'*.oRt*orT

D6255/DGS96-AOC-W-ENGG-OO3 Rev.00a- Welding consumable storage and Handling Page | 22

 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
EXOTIC WELDI NG CONSUMABLES

TABLE OF CONTENTS

SECTION TITLE

1.0 FLOW CHART

2.0 scoPE

3.0 PREVENTIVE ACTION

4.0 RESPONSIBILITIES

5.0 ATTACHMENTS

5.1 COLOR CODE CHART

5.2 WELDING CONSUMABLE REQUEST SLIP

5.3 TAGS TO BE ATTACHED NEAR EXOTIC BUTT JOINT.

PAGE 2 OF 8
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 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
EXOTIC WELDING CONSUMABLES

2.O SCOPE

This procedure covers the steps and controt measures required to be imptemented
for the issue and usage of exotic welding consumabtes.
Exotic wetding consumabtes are defined as :

3.0 PREVENTIVE ACTIONS

To avoid the mix up of wetding consumabtes, the foltowing steps to be undertaken.

Cotor code shatt be imptemented to exotic wetding consumables.

Each wetder shatt be issued a stip by the wetding leaderman/foreman to draw
consumabtes from the stores.
A> A dedicated and trained store keeper in place to issue consumables.
erolect specific color coded Tubes shatl be used for GTAW wetding
consumabtes.
Cotor code/tagged GTAW wires issued to each wetder. Note that onty one
type of consumabtes to issue to each wetder.
Balance consumabtes to be returned to the store at the end of each shift or
any change in job Assignment during the shift or when the job is compteted.
Periodic audit by Quatity Department to check comptiance.
Wetding consumabte for CuNi and Monet shatt be stored in a designated
A> container at site, segregated from other exotic wetding consumable
containers.

Refer to Section 4.0 Responsibil'ities.

4.O RESPONSIBILITIES

4.1 WAREHOUSE

with cotor code (GTAW, SMAW, SAW, GMAW & FCAW). White issuing boxes
,A. tnat contains more than one tube/packet, each tubes/packets shatl be
cotor coded Prior to issuance.

project & records project specific Job No. against which, issued.

PAGE 4 OF 8
 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
EXOTIC WELDING CONSUMABLES

4.2 CONSUMABLE AREA STOREIAAN AT SITE

A > The store keeper shatt have a clear understanding of this procedure.

the iubes & GTAW rods. Then open one tube at a time and color code atl
GTAW rods at both ends using sticker. Arrange PMI check after cotor
coding the wires from each tube before issuing to wetder. sMAw
electrodes are not required to have a cotor code sticker'

upkeep, controt & handl'e consumabtes as stated below'

r segregate att etectrodes by type and file test certificates.

o ExotiC etectrode of different types as specified in Clause 2.0 of this
document shatt be baked / re-dried separatety in any baking oven,
ptacing one type at a time. However different type/grades of
etectrodes shati be stored in separate hotding ovens with proper cotor
code identification.
. For exampte, etectrodes of Inconet, E309L-15 & E316L-17 may be
baked in the same oven one type at a time.
o Electrodes of lnconet, E3O9L-15 & E316L-17 shatt be stored in
separate hotding ovens per type with proper cotor code
identification.
o For baking / re-drying/ hotding guidetines shatl be as per Clause
5.0 of MD/W.ENG-005.
r Keep container locked when NOT in attendance.
I Etectrode hotding ovens shatl be painted or color code sticker
attached as per the code sticker attached as per the color code chart
in 5.1.
r lssue required quantity to wetders based onty on Leader man's request
stip (See Attachment).
r Record lD, date, quantity issued, type, etc. to wetder tube and with
Badge No.
r Discipl,inary action witt be taken on the responsibte person, who teaves
the work itation etectrodes consumabtes teft out as it is and not
/
returned.

4.3 WELDING ENGINEER

type and the appticable color code.

posted in the worksite.

4.4 WELD LEADERMAN

A > Shatt randomly check if the identification printed on the wire is

correct & tagged with the correct cotor code sticker'

PAGE 5 OF 8
 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
EXOTIC WELDING CONSUMABLES

assignment given to the wetder. He shatt make out consumabte request

stip for quantity to be issued to welder (See section 5'2)'

out unattended.

color coded and att the contents are correctly cotor code tagged'

4.5 WELDERS

n )
'/s\
Att wetders shatt verify cotor code tag and manufacturer's markings
on each wire/etectrode and confirm correctness upon receipt from
the store.

his teaderman if in doubt.

adjacent to the wetO. SrVtlW stubs shatt be cottected in cans or boxes.

4.6 QC INSPECTOR

LTCS Fietd joints , before wetding

stubs ends are verified against WPS as being correct (cotor code tags and
A. manufacturer's markings).

Additionat PMI check to be carried out for specific cases when in doubt.
Resutts shatt be recorded on the tag with date and further the wetd shatt
be cut-out or excavated as necessary.

stubs confirmed as compliant t Ptil checked (if any)" before submitting

the CIR to Certification.

PAGE 6 OF 8
 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
EXOTIC WELDING CONSUMABLES

5.0 ATTACHMENTS

5.1 COLOR CODE CHART

Methsd Statement fllS IVo.

J. Ray llcDermott
Erlbzr llm&pftrc&d. JRMEH-GEN-PROC.OO3
Ou!'/l, Wffi *.DEttfrrlt
Consumables Color REV.3
Codtng System Scqp.;
coroR csJrrc Fm nElDn c Gofsul sts
FOp sv SEGnEGlttor{ llflt [rEI{tFn txrr
ol Exoth Weitdhrg Concumtblr end Cubon
c(ocl Low T!{/nD{/rlturr wcldlng contumab/tr,a,
St,tfa ttfilt*'tdurna|D|. ||rrlnfunt r Coror Codt lltfr|tlluypo
AlVs Gh'rlficrdon Andenndn t{ lrbftr,{ofr.,
,ncsrf /lrofic, * ATAW I AUAW I SI,d-W I {'dtil r.ldrElbql?lbt
ERIgCtlb.S/ Sp.cr.rJrrft Sofid rncoltct 6?A 02, cs
I FItiO*laS ,twrtr/AZghlorcl 112 dpdlOl- tdth lrlrptrcl 626 / 825
''cot?.l

ERM' Sprtr,hrnaffi l'/otlE,l toCartptt Soel, e.g.

2 Ni'lC lhr M.l*.6',, ,twt/ tlodttrytobnco
tlbl(3,lWC|s'toEhctodp 111
EXI,|'N' ffi4poaJtffirg RodCo. sf/jdg/yIOCUM
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spacrarmr,t &lfttwloguNtor lorJu
4 6ROIM/FArN, p* O/fW
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^/oaol67, 187
Spccr.f trri'tr ,M,a.g. nwnl sltulhing
5 ER r'rEu 7/EAlnu 7 Monel &,
,tknel Wdttu Elx:furx'le ,fi
/l*rrnraftfir Anoil.. - LlncolnEffi'C Aludmium bonzc b CuNi
6 CfAlYrxkr GRICUTAIj,226
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ER 30,{) LI E 3(N L oK 16.5i / O'( 67,75 $d*tt Sctmtb/tart
ESAA FOr Gttoo,l ul?c, to D||trrsslt
t1 ER 309 r / 309 t oK 18.s1/ A( C7.20 L'EfiT CREEi' stut tw 1t 8L lt$l',,h sancifutt)

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 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
EXOTIC WELDING CONSUMABLES

5.2 WELDTNG CONSUMABLE REQUEST SL|P

DATE AUGUST 2,2005 PROJECT

SHIFT DAY SHIFT WPS # PP 3114

WELDER # 33230 STORE Tt,lAN 95134

CONSUMABLE AWS CLASS DIAAAETER QUANTITY COLOR CODE

BRAND/TYPE
INCONEL 625 ER NiCrMo-3 2.4 1 TUBE BLUE

ffi rf=f) N-|r)h UUU

Wetding Foreman : Area Store Keeper : Wetder:

Date : Date : Date :

5.3 TAGS TO BE ATTACHED NEAR EXOTIC & LTCS FIELD JOINTS.

ACCEPTABLE WPS FOR USE

. PP 3114
ACCEPTABLE WPS FOR USE
. PP 3115
. PP 3170
. PP 3196
. PP 3171
. PP 3197
. PP 3198

QC |NSP. SrG.

WELD L/M SIG.

WELDER SIG.

SANNPLE @NLY
PAGE 8 OF 8
 McDermott Arabia Company Ltd (lK) Saudi Arabian Oil Company (lK)
McDermott Middle East, Inc. (OOK! Aramco Overseas Company B'V
Contract Nos. D6896 (lK) and D6255 (OOK) Contract Nos.650003580a (lK) and 6600035821

oromco
APPENDIX 2 - PREVENTIVE ACTION PLAN FOR THE CONTROL

OF CHEVRON CRACKING

MDR-ME-L2-WT-005-APP2 (Click this link complete document)

aEV. r r oATfo: o*n .t.r*f. torr

J.lAYffrOtfrlSTT

PRTVEilTIVE ACTION PI-A].I FOR THE

coilTRoL oF cHwRox cRAcKlilG

I" lAYncDln*$rf

Nrfi* | ffl

D6255/D6896-AOC-W-ENGG-003 Rev.00a- Welding consumable storage and Handling Page I 23

 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
WELDING FLUXES TO AVOID CHEVRON CRACKING

TABLE OF CONTENTS

SECTION TITLE

1.0 FLOW CHART

2.0 SCOPE

3.0 CHEVRON CRACKING

4.0 PREVENTIVE ACTION

5.0 RESPONSIBILITIES

6.0 DIAG RA/\AETI C REPRESENTATION

COPYRIGHT CLAUSE

No part of these presents may be reproduced or transmitted in any form or by any means including photocopying and recording without the
written permission of the copyright holder, apptication for which shoutd be addressed to J. RAY McDERMOTT, P.O. Box 16961 Dubai' U.A.E-
Such permission must also be obtained before any part of these presents is stored in any retrieval $Atem of any nature.

PAGE 2 OF 8
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 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
WELDING FLUXES TO AVOID CHEVRON CRACKING

2.O SCOPE

This procedure covers the steps and controt measures required to be imptemented
for the issue and usage of wetding ftuxes to prevent Chevron cracking. Chevron
cracking is usuatty experienced in tong seam wetds of Tubutar / can.

3.0 CHEVRON CMCKING

3.1 What is Chevron Cracking?

. The cracks observed 45" to the tongitudinat section, perpendicutar to the

ptane of wetding ptates. These cracks are catted as Chevron Cracks,
Transverse 45' cracking; or Staircase cracking.

o The cracks are characterized by their orientations, which is approximately

45' to the ptane of the ptate in a butt joint.

FIG 1: Chevron Cracks

3.2 What are the possible reasons for Chevron Cracking?

o High residuat stress in the weldment causes this cracking - typicatty tong
seams of rotted Cans, joints between deck teg & ring plate.

e Low preheat & Interpass maintenance may lead to the stress generation /
residuat stresses, may finatty hetps to cause Chevron cracks, in conjunction
with hydrogen accumutation in those tocations.

r From research has conctuded that wetd metat hydrogen resutting from ftux
it
moisture ptays a key rote for the same issues.

. Chevron cracks are normatty observed in wetding of high basic aggtomerated

wetding ftuxes. But, with sufficient moisture present it coutd atso occur with
lower basicity or fused ftuxes.

PAGE 4 OF 8
 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
WELDING FLUXES TO AVOID CHEVRON CRACKING

4.O PREVENTIVE ACTIONS

4.1 Use Hot Welding flux :

1 Wetding Leader man shatt ensure that fl,uxes are property baked at 230'C -
300"C 7or Z hours and then hotd at 200'C titt it is issued for production
wetding. The same shatt be recorded in the monitoring card pasted on the
Baking / Hotding oven.

2 As a second tier of check point, each welder/welding operator witt check the
temperature monitoring card to confirm whether the fluxes are baked and
hotd' at specified templrature before taking ftux to the wetding station
/hopper for Production wetding .

i Before taking the ftux from the Baking / Hotding oven, each wetder /wetding
operator sha'lt take out at teast 2 or more paits of ftuxes from the oven and
put them back into the oven from the top; to ensure,tha_t wetding ftux issued
is sufficientty hot, temp shoutd be at teast above 200'C. The same may be
confirmed wittr Oigital temperature probe before putting the ftux into the
hopper

{ Before issuing /transferring ftux from ftux oven to the ftux hopper for
production wetding, each wbtder/wetding operator shalt aware that the ftux
-Adequate
property heated. PPE (inctuding gtoves) shatt be used white
handting the hot ftux.

5 This is appticabte onty for tong seam wetding stations onty (as a preventive
measure to ensure thit the ftux temperature is high enough & conforms the
above requirements).

6 Any break during wetding e.g. Lunch break, shift change ,any o_ther
fabrication sequences ; ftui from the hopper shatt be reptaced with hot flux
from the oven. This shatt be appl.icabte to ftux hoppers with or with out
heating arrangement.

7 Each wetder shatt check the temperature of ftux inside the ftux hopper as
specified ( 100'C) before starting any wetd ,otherwise ftux from the hopper
shatl, be reptaced with hot flux from the oven.

8 Any ftux suspected to be wet, damp or exposed to RH 80% max shall be

distarded oi redry at a baking temperature of 300"C min for 2 hrs or as per
manufacturer recommendation.

9 Periodic audit shatt be done by Quatity Department to check comptiance.

10 ln back wetding stations, wherein "Heating type Ftux Hopper" is not avaitabte,
in no occasion any ftux shatt be used for wetding which has been kept for
more that t hour prior to wel.ding. The ftux shatt be replaced with the fresh
ftux from the hotding oven.

PAGE 5 OF 8
 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
WELDING FLUXES TO AVOID CHEVRON CRACKING

4.2 Higher Pre-Heat Maintenance :

1. preheat shatt be maintained at minimum of 150"C for thickness of 1 inch

or above for Long Seam wetds; during high humid period of the year
(especiatty from Juty- August & October to February or any other weather
condition when RH is more than 80% in the atmosphere). This shatt be
considered as over and above conditions to the appticabte wPS.

Z. please note that this requirement is onty appticable for the period as
mentioned in 4.2.1.

5.0 RESPONSIBILITIES

5.1 WELD LEADERTAAN / FOREMAN

. Att leader men /foreman shatt instruct wetders / wetding operator

regarding the strict adherence of pre heating and close monitoring of the
same for the assignment given to the wetder / welding operator.

5.2 WELDERS / WELDING OPEMTOR

j ltt welders / wetding operators are responsibte for wetding in futt
comptiance to WPS, I-evet-it procedures for consumabte controt, ryf, his
leader man if in doubt.

5.3 QC INSPECTOR

. Dedicated qC inspector shatt ctosety monitor the adherence of

aforementioned Poi nts.

PAGE 6 OF 8
 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
WELDING FLUXES TO AVOID CHEVRON CRACKING

5.0 DIAGRAMETIC REPRESENTATION

Step 1: Check of Welding flux at Oven (baked / reheated/ holding, etc) and
issual from it

FLUX OVEN FOR

REHEATING/
BAKING AND
HOLDING OVEN

FLUX FROM HOLDING OVEN

SHOULD BE MIN 2OO'C

FIG 1 :- WELDING FLUX OVEN FOR BAKING / REHEATING / HOLDING

PAGE 7 OF 8
 PREVENTIVE ACTION PLAN FOR THE CONTROL OF
WELDING FLUXES TO AVOID CHEVRON CRACKING

6.0 DIAGRAMETICREPRESENTATION

Step 2: Check of Welding flux at FLUX HOPPER

FLUX HOPPER FOR

HOLDING FLUX
DURING WELDING &
MIN TEMPERATURE
SHALL BE 1OO'C

FIG 2 :. WELDING FLUX HOPPER FOR HOLDING FLUX DURING WELDING

Note:
1. Flux shatt be replaced each time if there is an intervat during wetding operation'
lny break during wetding e.g. Lunch break, shift change, any other fabrication
,"qu"n."t; flux?rom th6 hopper shatt be reptaced with hot.ftux from the oven'
This shatt be appticabte to i[ux hoppers with or with out heating arrangement
(inctuding back weld stations)
prior
Temperature of flux inside Wetding hopper shatt be maintained at teast 100'C
and during wetding.

PAGE 8 OF 8
 McDermott Arabia ComPanY ttd (lK) Saudi Arabian Oil ComPanY (lK)
McDermott Middle East, Inc. (OOK) Aramco Overseas ComPanY B.V
Contract Nos. D6896 (lK) and D6255 (OoK) Contract Nos.660003580a (lK) and 6600035821

oromco
APPENDIX 3 - OERLIKON CONSUMABLE BACK.UP FOR FLUX BAKING
TEMPERATURES

MDR-ME-12-WT-005-APP3 (Click this link complete document)

AIR LIAUIDE
ffiRUKplU
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Reconrmendation for storage and processlng
of aggbmeratrld low-hydrogen welding fiuxes

Storage.
Er usu* in trade, tre rekfinq llur 'ls erpplied in PE bagp al fr l4tt. Upon reque*t tre lhrx maU be
pac*ed h EIGBAS$- mux n PE{a93 mu$ le storgd in a dry ild ternpelatrre confdlcd room
uith mirimgm tenrperatne 15'C il6 abcotrb moisfi,Itg cmtent of max ll gram J kg *itr'
see graph bebry fw mn*indions Rtl & Enrperahre that comply b 1l grann/Bg alr-
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t ndcf #orye oorflifio|v lh6 lux trsy be $orE(t ftr one year provkled the pac|(irg ic no{ damagcd-
OERLfKOI| DRYBAC ir corphtefi rnnidure progt paclqing and requires no controled fitttslic
Fluret:uppled h'OERi-lKOfl DRYBAG can be ured 6rrrlding uiSFul awy nc'ufir
''6iht[.
tioning cr re-boting.
Sef66 u6c, pleare- choct Sro ,J@gf.qt d tre paching. lf fle bag sfitrE any sigffi of pemtsaling
&mqe frtd.rgn 0E fdl, fhen fi conientr of Orc @ must fpt be rlred. The fits( shotdd be
rEbofd Q hrx tl ffi - Xfi "Cl ot dir;atded-

.& UQUIDE faUW I t G.r{t+w' s'F r"^tx' rd

Page | 24
D6255/D6896-AOC-W-ENGG-OO3 Rev.00a- Welding consumable storage and Handling