DOC. NO.

REV
W153-8543-OK-QA/QC-015 0

PT. ADHI KARYA (Persero) Tbk

DATE 20-09-09 SHEET 1 OF 8

CONSTRUCTION SERVICE - WORK UNIT RATE

PACKAGE C NO. 8543 OK

WELDING MATERIAL CONTROL

PROCEDURE

Prepared by, Revied by, Approved by,

Bona Sitompul
QA/QC Supt. QA/QC-TF CPI

CONTENT
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CONTROL PROCEDURE Date : Nov 20, 2009
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1. SCOPE

2. REFERENCE

3. RESPONSIBILITY

4. RECEIPT OF WELDING MATERIAL FROM WAREHOUSE

5. STORAGE

6. HANDLING OF WELDING MATERIAL

7. ISSUE

8. USE AND RETURN

9. LOW HYDROGEN ELECTRODES AND FLUXES STORAGE AND BACKING

10. DOCUMENTATION

11. EXHIBIT

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1. SCOPE:
This procedure describes the requirements for controlling of all welding
material to be used in Fabrication,Instalation at Ho Project Duri,

2. REFERENCE:
PP-QC-GG-001 QA/QC Procedure
PP-QC-GG-006 Welding Procedure.
Vendor Specification

3. RESPONSIBILITY:
 The Welding Supervisor is responsible for the control of all welding
materials
 Welder/ Welding operator is responsible for request of welding material
 Warehouse man (Clerk) is responsible to record all the welding material.
 QA/QC Manager is responsible to Ensuring the proper system for control
of welding material has developed and implemented.
 QA/QC Coordinator is responsible to Ensuring this welding material control
procedure implemented within BBB operation. The welding material
manufacture has been existing in warehouse in order to ensure that the
welding material stored complies with welding material recommendation.

4. RECEIPT OF WELDING MATERIAL FROM WAREHOUSE:

4.1. Procurement and receiving of welding material shall be in accordance
with the applicable procedure of the manual.
4.2. Prior to receiving from warehouse, the Clerk shall assure all welding
material have been an ACCEPT Tag from QC Department (exhibit. A)
4.3. The following items shell be checked when performing receiving
inspection of material:
4.3.1. All Packages of welding material will be inspect by Visual
4.3.2. Check Specification of receiving material with refer to specification
and Purchase Order.
4.3.3. Check material Certificates in accordance with applicable code/
standard.
4.3.4. The welding electrode shall free from such harmful defects as the
exploitation of covering flux, cracks, dirt, deterioration, grease,
paint, rust etc.
4.3.5. Check Quantity of Material.

4.4. If any unacceptable welding material receive QA/QC Inspector shall be

rejected the material and material cannot use for the welding, QA/QC
Inspector is responsible to guarantee and disposition of material

5. STORAGE :
5.1. Warehouse

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CONTROL PROCEDURE Date : Nov 20, 2009
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 Welding electrodes and filler rods shall be storage in a separate place

in the warehouse. Welding electrodes and filler rods shall be stored
orderly and separately by type labels or marking so they can be
identified easily to avoid mixing.
 All welding materials shall not be put directly on the floor. They shall
be placed on wood supports at last ±5 “ above from the floor.

5.2. Condition of Storage

Storage Condition of welding material shall be as follows:
 Package of welding electrodes and filler rods shall not be stored
directly on the ground.
 Package of welding electrodes and filler rods shall kept away from any
humidity.
 Package shall not be opened until just before use.

6. HANDLING OF WELDING MATERIAL

All welding material shall be handled carefully to avoid damage contents in
the damage containers shall be checked for surface contamination and
damage of welding material. The welding materials which show evidence of
handling damage shall be controlled in accordance with the Correction of
Nonconformity material.
The requirements of welding electrode handling shall be in accordance with
code/ standard and manufacturer’s recommendation.
1. Drying
The moisture content covering flux low hydrogen electrodes shall be
removed, with the limit as specified in ASME sect. II part C table A2.
Electrode dryer method may be use in order to remove the moisture from
the covering flux and recommended heating temperature of 260° C to 427°
C at minimum one hours or manufacturer recommendation.
2. Drying Warming (Holding oven storage)
In order for low hydrogen electrode to be designated as low moisturizing
absorbing, shall be expose to an environment temperature at range of
30°C ~ 140°C on the holding oven storage.
3. Re-Drying
Electrodes that had been issued for use but have not been used within
that day, electrode shall be re-dried in accordance to item 1 this section
but no more than one time.
4. Drying and Warming.
a. Drying Oven
Drying oven is for drying and re-drying the electrodes that conform to
the requirements. Drying ovens shall be able to consistently control the
drying temperature and holding time
b. Keeping (storage) Oven
Keeping (storage) Oven is a holding chamber only for field storage
electrodes in order for a low hydrogen electrode to be designated as
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CONTROL PROCEDURE Date : Nov 20, 2009
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low moisture absorbing. The storage chamber temperature shall be

kept at temperature range of 30° ~ 140°C all the time be used for this
purpose.

c. Portable Dryer
Each welder shall have at last one portable dryer. One portable dryer
shall be lit to one type of welding electrode. During welding work
portable dryer shall be kept at temperature range of 30° ~ 140°C.

7. ISSUE:
a. Welders/ welding operators shall request the welding materials to
Warehouse Man/ Clerk by using the “Welding Consumable Request”
(exhibit B) which has been signed by welder foreman to make sure that
only the right material are used and ensure that only sufficient are drawn
for the particular work period as per Table 1.

b. The Warehouse Man (Clerk) shall record the heat no./ lot no. , quantity
issued and exposure time allowed on the material issue Note (exhibit C)
and ask to welder/ welding operator for his signing.

8. USE AND RETURN:

 The welder or welding operator shall make welding with specified filler
metal in accordance with the relevant of applicable WPS.

 When the Welder or Welding operator has completed the assigned

welding or allowed maximum exposure time is reached, he shall return
some unused filler metal to the Warehouse Man/ Clerk. The Clerk shall fill
out quantity returned on the Material Issue Note.

 The Warehouse Man/ Clerk shall check for the damage or contamination,
and put the returned welding materials in separate container and re-bake
prior to issue again after marked by red paint on the end of the electrodes.
The damage material shall be rejected.

 The electrodes which have been re-baked more than one time shall not be
used for the Code items.

 Covered electrodes of fluxes which have been exposed to become damp

must be scrapped.

 When all of the filler metals in single box such as carton are consumed,
the box shall be removed from the welding Oven and shall be destroyed.

9. LOW HYDROGEN ELECTRODES AND FLUXES STORAGE AND

BACKING:
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7.1. Baking and Holding Equipment

 The welding material oven are electrically heated equipment which
shall be prepared sufficiently so as to bake or hold electrodes or fluxes
in accordance with Manufacturer’s recommendation and the code
requirements. The welding material oven shall be used for baking of all
low hydrogen type electrodes and holding the baked or hold electrodes
or fluxes at the specified temperature.
 The portable warmers may be used to maintain the electrodes in a dry
condition after issuing from the baking and holding oven or furnaces.

7.2. Baking and Holding Requirements of covered electrodes.

1. All electrodes and fluxes shall be re-baked in accordance with this
procedure, when the original sealed container is opened for use or the
continued exposure time for low hydrogen coated electrodes to
atmospheric conditions exceeds the time indicated in the following
table 1.

TABLE 1

ELECTRODE (AWS CLASS) EXPOSURE MAX. HOURS

E 70 xx Series 8
E 80 xx Series 4
E 90 xx Series 3
E 100 xx, E 110 xx Series 2
E 300 4
Other than low hydrogen type
8
electrodes

a. After baking the electrodes shall be placed in the holding oven, or

the portable warmer at a temperature of least 30° C~ 140°C.
b. Re-baking shall be performed on any electrodes exposed to the
atmosphere for a period of more than such hours as indicated in the
table 1 without being returned to the portable warmer.
c. The baking of fluxes shall be performed prior to use and rich rust
flux shall not be used.
d. All covered electrodes which have been wet or damage shall not be
re-baked. They shall be rejected.
e. Mid steel covered electrodes other low hydrogen electrodes may be
used directly from the as-received container provided it has not
been damage or not been exposed to atmosphere, moisture or
contaminants.
f. The exposure time is defined as that period of time the electrodes
are exposed to atmosphere.

2. Baking, Holding Temperature and Duration Suggested.

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Baking, Holding Temperatures and time for each type of electrodes

and flux are specified in the following Table 2.

Drying
Holding
AWS (Class) Ambient Air Drying Period
Oven
(Minute)
E 7015
E 7016 30 ~ 140 °C
1/2 hours at
E 7018 Not above
temperature 60 ~ 120
E 7028 Recommended ambient
260° ~ 427°C
E 7018 M temperature
E 7048

Note: The drying and holding electrode shall follow manufacturer recommendation.
3. When the next operation on the Erection is welding, the shop Foreman
shall notify the Clerk of the required material so that the Clerk may
bake the welding material.

10. DOCUMENTATION:
The Material issued note shall be maintained by the clerk. The clerk shall
collect the material Issue Note and check the use welding materials.

11. EXHIBIT:
Exhibit A: Acceptance Tag.
Exhibit B: Welding Consumable Requested
Exhibit C: Material Issue Note.

AXHIBIT A: ACCEPTANCE TAG

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PT. ADHI KARYA (Persero ) tbk

ACCEPTANCE TAG

W/O NO. :
ITEM NO. :
RIR NO. :
RIR Serial NO. :
INSPECTOR: :

EXHIBIT B: WELDING CONSUMABLE REQUEST

PT. ADHI KARYA (Persero ) tbk

WELDING CONSUMABLE REQUEST

ELECTRODE / FLUX REQUESTED
W0. NO ITEM NO. WPS NO. WELDER
AWS NO. DIA (mm) QT’Y

RIAU,____________________
_____
SIGNED BY: REQUEST BY:

_________________ ________________________
CLERK WELDER FOREMAN

EXHIBIT C: MATERIAL ISSUE NOTE

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NO DATE TIME WO. ELECTRODE WELDER QUANTITY SIGN

HEAT/ RETURNED
AWS. NO NAME SYMBOL REQUESTED WELDER CLERK
LOT NO. KG TIME

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