Академический Документы
Профессиональный Документы
Культура Документы
by ASXU, Anton
Anton Senger
Date:
2022.04.21
Senger 15:17:54 +05'00'
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ Дата 22.03.2022г.
ХРАНЕНИЕ
Версия 04
PROCEDURE FOR HANDLING AND STORAGE OF Date 22.03.2022 y.
ELECTRODES Version 04
Страница 4 из 21
2. Ссылки
3. Термины и определения
Ответственные лица
Обязанности
Начальник участка Несет ответственность за применение данной процедуры, за
управление работами в соответствии с техническими
условиями проекта, принимая во внимание критерии
функциональности, безопасности и качества. Несет
ответственность за хранение и транспортировку
присадочных материалов для сварки
Инженер по сварке Несет ответственность за определение технических
требований до осуществления закупа расходных сварочных
материалов
Кладовщик Несет ответственность за хранение и выдачу расходных
сварочных материалов для сварки
Менеджер КК Несёт ответственность за проведение аудита в целях оценки:
текущего состояния касательно применения требований
данной процедуры.
текущего состояния соответствия с требованиями,
удовлетворяющими производство и Компанию
Инженер по Несет ответственность за проведение периодичного
контролю качества контроля за правильным хранением сварочных
механомонтажных работ расходных материалов на строительной площадке.
Проверяют исправность оборудования для хранения
сварочных расходных материалов на площадке.
Проверяют сварочные расходные материалы на
предмет механических повреждении, целостности
вакуумных упаковок перед началом сварочных работ
Сварщики: Несут ответственность за хранение сварочных
расходных материалов, полученных со склада для
выполнения определенных работ. При получении со
склада сварщик должен проверить пачку на предмет
механических повреждении и удостовериться в
целостности пачки, после получения и фиксации в
журнале сварщик на рабочем месте перед выполнением
работ, фиксирует время, дату и клеймо на пачке. После
завершения сварочных работ в конце смены, сварщик
обязан вернуть на склад или в инструменталку остатки
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ Дата 22.03.2022г.
ХРАНЕНИЕ
Версия 04
PROCEDURE FOR HANDLING AND STORAGE OF Date 22.03.2022 y.
ELECTRODES Version 04
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5. Описание процедуры
5.1 Получение расходных сварочных материалов
5.2 Хранение
5.4. Прокалка
Охлаждение с Охлаждение с
Температур Скорость Время печью при
Температур печью при
а в печи при подъёма выдержк
Наименование
УОНИИ-13/55
BOHLER FOX 150
150 100-200 300 -350 2 200
EV 50
6. Приложения/ Appendix
Date/Дата
Manufacturer/Производитель
Filler
ELECTRODES
материал
Issued, kg/Выдано, кг
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ
Project/№ проекта
Returned, kg/Возвращено кг
Версия 04
Version 04
Date 22.03.2022 y.
Дата 22.03.2022г.
Страница 11 из 21
Note/Примечание
Журнал выдачи расходных сварочных материалов /A log issuance of consumable
Приложение А/ Appendix A
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ Дата 22.03.2022г.
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PROCEDURE FOR HANDLING AND STORAGE OF Date 22.03.2022 y.
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Приложение Б/ Appendix Б
Журнал учета температуры и влажности воздуха на складе хранения сварочных
материалов/A log of temperature and humidity control in a warehouse for storage of welding
consumables
Date/
Дата
Manufacturer/
Производитель
Diameter mm/диаметр мм
ХРАНЕНИЕ
ELECTRODES
начала прокалки
Temperature of baking
ºC/Температура прокалки
Version 04
Quantity kg/Количество кг
Date 22.03.2022 y.
Дата 22.03.2022г.
Страница 13 из 21
Responsible
signature/Подпись
Note/Примечание
Журнал прокалки сварочных материалов/ A Log of welding consumables baking
Приложение В/ Appendix B
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ Дата 22.03.2022г.
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PROCEDURE FOR HANDLING AND STORAGE OF Date 22.03.2022 y.
ELECTRODES Version 04
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2. References
Welding materials entering the warehouse must undergo a visual inspection (quantitative and
qualitative control) with the appropriate initial arrival documentation. After that the Certificate of
incoming control is executed according to DP-18 - Incoming control.
External acceptance of welding materials is performed by a commission composed of a welding
engineer, warehousemen, representatives of the CC and supply department.
When receiving consumables such as electrodes and filler wire, a person the applicant for the purchase
checks the received material, the input control engineer, checks the availability of available certificates
according to requirement 3.1 or 3.2 (testing of each lot or heat), as well as their compliance with the
requirements for carbon steels:
1) Sharpie impact test in both welded and heat treated condition at (minus) -40°C and below. Acceptance
level - min 27J. : Test temperature, horizontal expansion values and absorbed energy must be recorded
(ASME II Part C, AWS B4.0)
2) Tensile test in both welded and heat treated condition. The results of the joint metal tensile test shall
include at least Yield Point, Elongation, Tensile Strength and Test Temperature (ASME II Part C, AWS
B4.0)
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ Дата 22.03.2022г.
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Версия 04
PROCEDURE FOR HANDLING AND STORAGE OF Date 22.03.2022 y.
ELECTRODES Version 04
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3) The hardness test for Vickers HV10 shall be carried out both after welding and heat treatment
Acceptance criterion - max. 220 HV10 both after welding and heat treatment. Test site - according to
NACE MR0175/ ISO 15156-2, Fig. 2 for the part of floated metal.
For stainless steels:
1) Sharpie impact test after welding at (minus) - 140°C or lower. Acceptance level - min 27J. Min.
Writing: Test temperature, horizontal expansion values and absorbed energy must be recorded (ASME II
Part C, AWS B4.0)
2) Tensile test after welding. The results of the joint metal tensile test shall include at least Yield Point,
Elongation, Tensile Strength and Test Temperature (ASME II Part C, AWS B4.0)
3) The hardness test for Vickers HV10 shall be carried out after welding, the acceptance criterion shall
be max. 220 HV10. Test site - according to NACE MR0175/ ISO 15156-2, Fig. 2 for the floated metal
part
4) the ferrite content in the austenitic stainless steel weld seam metal should be in the interval between
3FN and 10FN when measuring the magnetometric equipment calibrated according to the standard
procedure AWS A4.2.
5) Chemical analysis of stainless steel/nickel alloy consumables should be performed on weld joint
floated metal for each batch of welding consumables. It shall be performed either:
I. On test plates for each batch of consumables; whether
II. Based on the material of the test drilling of each working weld joint taken from the surface, which is
exposed to the environment of the technological process.
III. The analysis shall meet the requirements of ASME SFA 5.4 for the specified stainless steel/nickel
alloy grade.
Only consumables that meet all the requirements listed above, including the appropriate packaging, type
and correct certificate, are allowed.
All welding materials must be packed in appropriate packaging that protects against mechanical
damage in accordance with the requirements
of regulatory documents approved in accordance with the established procedure. The surface of the
wire should be clean and smooth, without cracks, delaminations, films, folds, blisters, chipping, scale,
rust, oil and other contaminants. Notches (including lagged ones), scratches, local cratering and
individual dents are not allowed on the surface of the wire.
In case of breach of packaging, welding materials are subject to the control of the condition of the
materials in order to make an appropriate decision on further use.
Accepted welding electrodes are stored in the electrode room, in accordance with the manufacturer's
requirements. Different materials are placed on different shelves, in order to avoid erroneous
issuance. Defective electrodes (if any) are stored separately in the quarantine zone and are marked as
"DEFECTIVE" and are used only for training.
5.2 Storage
All welding consumables shall be stored and applied in accordance with the manufacturer’s
instructions.
The consumables for welding shall be stored in a storeroom in a sealed packaging inside a clean dry
room with a controlled microclimate. The warehouse must be equipped in accordance with the
requirements of construction, sanitary, fire safety standards and regulations. The list of necessary
equipment includes, at a minimum, but not limited to:
1) local exhaust ventilation (workplace where control, weighing, packaging of electrodes, powder
wire and fluxes is carried out);
2) natural and/or artificial lighting;
3) thermohygrometer;
4) air and/or other type of heating;
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ Дата 22.03.2022г.
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A responsible person who receives electrodes from the warehouse is appointed by order for use,
baking, storage in the oven and delivery of electrodes. All welding materials are issued from the
warehouse and registered in the Consumable Welding Material Issue Journal (Annex A) in new sealed
packs. The electrodes and the welding wire shall not be stored in bulk on the site.
In order to avoid possible damage to the welding wire, it should be kept in dry heated spaces at a
temperature not less than plus 15оC in conditions that prevent contamination, humidification and
mechanical damage.
The use of welding materials is prohibited in case of any defect. The surface of the wire should be
clean and smooth, without cracks, delamination, films, folds, blisters, chipping, scale, rust, oil and
other contaminants. Notches (including lagged ones), scratches, local cratering and individual dents
are not allowed on the surface of the wire.
Welding wire in the workplace must be contained in its original packaging.
Electrodes in vacuum packaging can be transferred directly to the welding team.
At the moment when the welders open the vacuum packaging, the welder must record the date, the exact
time of opening and register the welder's stamp.
The number of issued electrodes at the beginning and end of each shift is entered into the database at the
warehouse/tool room. A hard copy of the Journal of the issuance of consumable welding materials
(Appendix A) is kept by the Person Responsible by order for the issuance of electrodes.
Unused welding electrodes are re-baked for 9 hours as described in paragraph 5.4. Moreover, only one
re-bakingis allowed.
Electrodes with a low hydrogen content obtained at the end of the shift and 9 hours after opening the
package are baked again and issued the next day. This action can only be performed once.
Welding electrodes released to welders for direct use are stored
in heated quivers at a temperature of at least 75°C.
After the warehouse employee has issued welding materials, the welder is responsible for welding
materials, and he is obliged to return unused welding materials to the warehouse or to the tool room, the
remnants of welding materials are further baked and put to work.
5.4 Baking
The baking of consumable welding materials is carried out in furnaces in the furnace conditions as
defined in the recommendations of the manufacturer. The required baking temperature shall be
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ Дата 22.03.2022г.
ХРАНЕНИЕ
Версия 04
PROCEDURE FOR HANDLING AND STORAGE OF Date 22.03.2022 y.
ELECTRODES Version 04
Страница 18 из 21
compared with the manufacturer’s recommendations on the package, on the certificate (if necessary),
the thickness of the layer and the weight of the electrodes when baking, is carried out according to
the certificate of the manufacturer of the electric furnace for drying and baking of welding electrodes
PSP20-400. Use heat-resistant paint in cans (red or black, heat-resistant up to min. +400°C) to mark
the electrodes to be re-baked, and the baking of corrosion-resistant alloys should be carried out in
separate furnaces and in a dedicated shop area with low chloride heat resistant paint in spray cans.
The baking modes of the most commonly used materials are shown in Table 1.
The conductor electrodes shall be placed on the grille installed in the furnaces, in layers not exceeding
50 mm high (unless otherwise specified in the manufacturer’s recommendations). When loading
coated electrodes, powder wire and fluxes, an entry is recorded in the «Welding Materials Baking
Journal» (Annex B). The log must be numbered, dated and stamped, and filled in by the site manager,
specifying the exact time of the inserting and the hold time of the electrodes. (Table 1).
УОНИИ-13/45А
УОНИИ-13/55 150
Electrodes
Baked welding electrodes may be stored in ovens with a temperature between 120 and 150 0C.
The furnace is inspected at the time of its commissioning, after repair (including replacement of
heaters, linings and other components of the furnaces that affect the heat treatment of the welding
materials) and during operation at least once a year.
The shelf life of the furnace shall be limited to the date of its next check-up, to be recorded in the
report. The Quality Engineer ensures that furnace certification deadlines are met at centralized
welding facilities.
Issue of consumable welding materials for welding works is carried out only by storekeepers who fill
in «Welding Materials Issue Journal» (Annex A).
Only one type of consumable welding material should be issued to welders, either manual arc or filler
wire; except when welders weld under combined welding procedures.
All electrodes, including low-hydrogen electrodes and stainless steel or nickel alloy electrodes
(irrespective of the type of factory packaging) shall be contained in the heated portable container
(heated quiver) switched on at the workplace.
Welding wire in the workplace should preferably be contained in its factory packaging and be
removed immediately prior to use.
The wire shall not come into contact with dirty, oily surfaces or surfaces which could potentially
disturb the protective factory coating. Rust wire shall not be used.
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ Дата 22.03.2022г.
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PROCEDURE FOR HANDLING AND STORAGE OF Date 22.03.2022 y.
ELECTRODES Version 04
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The welding material shall be used within the parameters recommended by the manufacturer.
If in the process of use there is any suspicion that the welding material does not meet technological
requirements, the material should be immediately transferred to the quarantine zone.
All unused welding consumables must be returned to the point of issue by the end of each shift and
stored in accordance with paragraph 5.2 of this procedure. The person responsible for the
welding/repair work (site master, section manager, etc.) is responsible for the return of unused
welding material.
Unused electrodes shall be re-baked for more than 9 hours, with only one re-baking allowed.
Low-hydrogen electrodes obtained at the end of the shift and 9 hours after the opening of the
package are added again and released the following day. This action can only be performed once.
ПРОЦЕДУРА ОБРАЩЕНИЯ С ЭЛЕКТРОДАМИ И ИХ Дата 22.03.2022г.
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ELECTRODES Version 04
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Ф.И.О.
Номер листа /№ of sheet Дата введения
ответственного
Номер Дата внесения изменения в
за внесение
изменения изменения действие /Date
изменен изъятого изменений
/№ of Нового /Date of of
/Name of person
amendment ного/am / new
/with amendment implementation
ended drawn responsible for
of change
amendment
1 - - - 11.01.2019 Abdulla A.
2 18.03.2019 Сагитов Р.
3 02.11.2019 Абжанова Б.