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RESID FLUID CATALYTIC

CRACKING (RFCC) PROJECT


PT. PERTAMINA (PERSERO)
WELDING MATERIAL CONTROL

Doc. No. :
RFCC-C-PR-PC-1140-006-0
Rev. No. :
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PROCEDURE

PROJECT

: RESID FLUID CATALYTIC CRACKING (RFCC) PROJECT

LOCATION

: PERTAMINA RU-IV CILACAP, CENTER OF JAVA

PERTAMINA

: PERTAMINA (PERSERO)

CONTRACT NO.

: 15/C00000/2011-S2

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Doc. No. :

RESID FLUID CATALYTIC


CRACKING (RFCC) PROJECT
PT. PERTAMINA (PERSERO)

RFCC-C-PR-PC-1140-006-0
Rev. No. :

WELDING MATERIAL CONTROL

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PROCEDURE

ISSUED FOR APPROVAL

REV.

DESCRIPTION

DATE

NI

YC

SI

PREPARED

REVIEWED

APPROVED

BY

BY

BY

REVISION HISTRORICAL SHEET

REV.

PAGE /

ITEM

DESCRIPTION OF CHANGE

PARAGRAPH

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CRACKING (RFCC) PROJECT
PT. PERTAMINA (PERSERO)
WELDING MATERIAL CONTROL

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Table of Contents
Section
1.0

Title
SCOPE

2.0

REFERENCES

3.0

TERMS AND DEFINITIONS


3.1

Contractor

3.2

SubContractor

3.3

Drying (Baking)

3.4

Keeping (Warming)

3.5

Re-drying

3.6

Unusable Electrodes

4.0

RESPONSIBILITIES OF THE SUBCONTRACTOR

5.0

RESPONSIBILITIES AND RIGHTS OF CONTRACTOR

6.0

RESPONSIBILITIES OF WELDING MATERIAL CONTROLLER

7.0

WELDING MATERIAL CONTROL

8.0

CONTROL OF STORAGE

9.0

8.1

Warehouse

8.2

Storage Conditions

CONTROL OF DRYING AND HOLDING


9.1

Equipment for Drying

9.2

Control of Drying, Re-drying and Holding

10.0

WELDING MATERIAL REQUEST CONTROL

11.0

CONTROL OF DELIVERY OF WELDING MATERIAL


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RESID FLUID CATALYTIC


CRACKING (RFCC) PROJECT
PT. PERTAMINA (PERSERO)
WELDING MATERIAL CONTROL

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PROCEDURE

1.0

12.0

RETURN OF WELDING ELECTRODE TO THE SHOP

13.0

IDENTIFICATION OF WELDING MATERIAL

14.0

APPENDIXES

SCOPE
This document provides the standard practice for controlling the welding materials
(welding electrode and rod) to maintain the sufficient quality of welds in the welding
of construction work including shop fabrication of structural, piping and Tank at field
for Resid Fluid Catalytic Cracking (RFCC) Project.

2.0

REFERENCES
The latest edition of following code / standard shall be referred as a part of this
specification:
AWS D1.1

: Structural Welding Code

ASME Section II Part C

: Specification for Welding Rods, Electrodes,


and Filler Metals

3.0
3.1

TERMS AND DEFINITIONS


Contractor
Contractor shall mean consortium of PT. Adhi Karya Tbk and GS Engineering
& Construction

3.2

Subcontractor
Subcontractor shall mean a firm / construction company who is awarded the
contract by Contractor to execute construction activities.

3.3

Drying (Baking)
Prior to issue the specified low hydrogen electrodes for carbon steel, low
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CRACKING (RFCC) PROJECT
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WELDING MATERIAL CONTROL

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alloy steel and austenitic stainless steel, they shall be dried to reduce the
humidity contained in the coated flux in accordance with Appendix -1 Drying
Conditions of Electrodes. Drying of electrodes shall be in accordance with
the manufacturers recommendation.
3.4

Keeping (Warming)
After drying, the electrodes mentioned above shall be kept at a temperature
range of 100 0C 140 0C or shall be in accordance with manufacturers
recommendation in the holding oven to prevent them from absorbing
additional humidity / moisture.

3.5

Re-drying
Electrodes that had been issued for use but have not been used within that
day shall be re-dried in accordance with para. 3.3 but no more than one
time.

3.6

Unusable Electrodes
Means used electrodes or unused electrodes that have defects, such as lack
of flux, wet flux or change in quality of flux. Electrodes that have been redried and still remain unused on the next issuance day are considered
unusable electrodes.

4.0

RESPONSIBILITIES OF THE SUBCONTRACTOR


(1)

The Subcontractor shall be wholly responsible for controlling welding


material which includes receiving, storage, drying, keeping, issue, return, redrying and re-issue of welding materials.

(2)

The Subcontractor shall establish its own welding material control procedure
based on this practice and shall submit it to Contractor to obtain approval
prior to the commencement of any welding work.

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(3)

The Subcontractor shall establish a centralized welding material storage and


control room, which may be located inside its warehouse or site workshop.
Appendix-2 provides an example. In addition, a satellite welding material
control crib may be provided at site, if necessary.

(4)

The Subcontractor shall provide and maintain all necessary equipment and
facilities for welding material control, such as drying and keeping ovens,
portable dryer (quiver) to each welder, Gas Tungsten Arc Welding (GTAW)
rod box or container to each welder, and so on.

(5)

The Subcontractor shall assign a full time Welding Material Contoller(s),


hereafter called WMC in charge of the above activities and under the
supervision of the Subcontractors QC or welding engineer.

(6)

The Subcontractor shall be responsible for all welding material control during
daily production welding at both site and workshop location. This includes
the correct usage of each type of welding electrodes/rods, provision of a
portable dryer (quiver) to each welder and its handling, daily house-keeping
after welding work so as to clear all used and unused welding
electrodes/rods from site and workshop, etc.

(7)

The Subcontractor shall be responsible for estimating the total required


quantity of each type of welding electrode and rod for the project,
procurement of them from a Contractor approved manufacturer(s), periodical
inventory checks and additional procurement during the construction stage
in order to secure the construction schedule and avoid shortage of welding
materials at the construction site. When requested by Contractor, the
Subcontractor shall submit its procurement plan and welding material
inventory status to Contractor for information.

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5.0

RESPONSIBILITIES AND RIGHTS OF CONTRACTOR


(1)

Contractor shall review the Subcontractors welding material control


procedure and approve it prior to the commencement of welding work.

(2)

Contractor shall check the Subcontractors welding material control room


and facilities prior to the commencement of welding work.

(3)

Contractor has the right to monitor and check implementation and


effectiveness of the Subcontractors welding material control at any time and
to provide advice or instructions on the same and require its improvement.

(4)

Contractor shall perform spot checking of welders portable dryers (quivers)


to confirm that proper keeping and warming conditions are applied, the
correct usage of each type of welding material, and confirm that welding
work is performed by welders qualified for the material being used.

6.0

RESPONSIBILITIES OF WELDING MATERIAL CONTROLLER


(1)

Welding Material Controller shall have sufficient knowledge of each type of


welding electrode and rod to be used for the project in order to prevent
mixing and/or mis-issue, and to carry out proper storage and drying of
electrodes.

(2)

Welding Material Controller shall be responsible for welding material control


including storage, drying, keeping, re-drying and issuing in accordance with
the established procedure and under the supervision of the Subcontractors
QC or welding engineer.

7.0

WELDING MATERIAL CONTROL

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Subcontractor shall submit material certificate of welding electrodes and rods to
Contractor for review and approval. Subcontractor shall submit the detail plan for
the welding material control to Contractor for approval prior to commencement of
welding work, which consists of the following items:
1)

Organization and responsibilities.

2)

Work flow chart or description of control sequence.

3)

Numbers of welding material controllers.

4)

Layout plan of welding material control room.

The welding material control system shall be monitored periodically by Contractors


Inspector during Subcontractors operation.

8.0
8.1

CONTROL OF STORAGE
Warehouse
Welding electrodes and rods shall be stored in a separate place in
warehouse. Welding electrodes and rods shall be stored orderly and
separately with labels or marking so that they can be identified easily to
avoid mixing.

8.2

Storage Conditions
Storage conditions of welding material shall be as follows:
(1)

Package of welding electrodes and rods shall be kept away from any
humidity.

(2)

Package of welding electrodes and rods shall not be stored directly


on the ground.

(3)

Package shall not be opened until just before use.

(4)

Welding materials storage shall be in such way that older stocks are
issued first.

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(5)

All GTAW filler wires shall be de-greased prior to use.

9.0 CONTROL OF DRYING AND HOLDING


9.1

Equipment for Drying


(1)

Drying Oven

Drying oven is used for drying and re-drying of the electrodes that conform
to the requirements of para. 3.3. Considering the capacity of each drying
oven and the total quantity of welding electrodes to be used in one day,
drying ovens shall be able to consistently control the drying temperature and
holding time. Oven, dryers, quivers shall be calibrated every 3 months.
(2)

Holding Oven

Holding oven is used to maintain storage temperature of welding electrodes


that conform to the requirements of par. 3.4. Sufficient numbers of holding
ovens shall be provided considering the capacity of ovens and the quantity
of welding electrodes to be used.
Holding ovens shall be kept at a temperature range of 100 01400 C at all
times.
When the quantity of welding electrodes to be used in one day is small,
drying oven described above may be used for this purpose.
(3)

Portable Dryer

Each welder shall have at least one portable dryer. Welders stamp number
shall be clearly marked on his portable dryer. One portable dryer shall be
limited to one type of welding electrode. During welding work, the portable
dryer should be kept warm at a minimum temperature of 70 0C.
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9.2

Control of Drying, Re-drying and Holding


Control of drying, re-drying and holding storage shall be carried out by
Welding Material Controller (WMC) in accordance with Appendix-1.
The drying oven and holding storage oven shall be clearly marked to show
the type of electrodes contained.

10.0

WELDING MATERIAL REQUEST CONTROL


When requesting welding material, Welding Foreman or Welding Supervisor shall fill
in the Welding Material Request Card (hereinafter called WMRC) showing the
required type and quantity of welding electrodes and welding rods to be used for
next day by each welder, and submit it to WMC by 4 p.m. of the provisions day of
delivery.
The welder shall not request the welding material directly to WMC.
Upon receipt of the WMRC, WMC shall prepare for issuance on the next day as
follows:
(1)

Check the total quantity and type of the welding materials requested.

(2)

Check the stock quantity and type dried and returned / re-dried on the day.

(3)

The WMC shall review the required quantity of electrodes to be dried for
delivery on the next day.

11.0

CONTROL OF DELIVERY OF WELDING MATERIAL


(1)

A portable dryer shall be provided to each welder for welding electrodes


storage and keep them warm at work site and the welding electrodes shall
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be delivered into the portable dryer directly. For TIG rods, empty boxes of
TIG rod may be used.
The portable dryers shall be collected and sent to the welding material
storage area for emptying and safe keeping at the end of each working day.
(2)

Supervisor or Welding Foreman shall come to the welding material control


room to receive the replenished portable dryers for each welder under his
supervision every morning.

(3)

Maximum issue amount of electrodes for one delivery shall be limited to 5 kg


per each portable dryer.

(4)

Electrodes which have been redried and kept for a long time shall be issued
first.

(5)

12.0

Prior to delivery, WMC shall check the following points:


-

Confirm the contents of the WMRC.

Check the quantity and type of welding electrode against the request.

RETURN OF WELDING ELECTRODE TO THE SHOP


(1)

Supervisor or Welding Foreman shall gather the portable dryers and TIG rod
from each welder and return to the designated place at the welding material
control room at the end of each day. No electrodes shall be left at
construction site or work shops.

(2)

Prior to return the welding materials, Supervisors or Welding Foreman shall


segregate unusable electrodes and inform WMC for their disposal. When
electrodes that are not used on that day remain in the portable dryer, WMC
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shall take out and stock separately for re-drying or disposal as required.
13.0

IDENTIFICATION OF WELDING MATERIAL


To avoid mixing and misuse of welding materials, all materials shall be made
identifiable with original marking or color coding after removal from its original
container.
All SMAW electrodes and GTAW rods being issued and used without original
marking shall be provided with color coding to identify their brand names or AWS
numbers.
Color code table to be used for RFCC Project shall be provided by Contractors
QAQCM. WMC shall be responsible to verify all electrodes and rods being correctly
color coded at the time of issuance. During production welding, Contractors QC
Inspector(s) and Subcontractors Welding Inspector (s) shall check color code /
identification marking as daily basis for correct usage.
A sample of color code table is exhibited in Appendix-5.

14.0

APPENDIXES
Appendix-1 :

Drying Conditions of Electrode

Appendix-2 :

Welding Material Control Room and Facilities (Example)

Appendix-3 :

Flow Chart of Welding Material Control

Appendix-4 :

Welding Material Request Sheets (Sample Form)

Appendix-5 :

Color Code Table of Welding Rods and Electrodes (Example)

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