Welding consumable control

1. DUNG QUAT REFINERY
DUNG QUAT REFINERY
PROJECT
PROJECT

2. WELDING CONSUMABLE
WELDING CONSUMABLE
CONTROL
CONTROL

3. PURPOSE
PURPOSE
To avoid misuse of welding
electrode
To provide welders with good
condition electrode in order to get
sound weld

4. RESPONSIBILITY
RESPONSIBILITY
 TPC’S QC – MONITOR
TPC’S QC – MONITOR
 SUBCON’S QC MANAGER – Audit / SUPERVISION
SUBCON’S QC MANAGER – Audit / SUPERVISION
 SUBCON’S QC – MONITOR & SURVEYING
SUBCON’S QC – MONITOR & SURVEYING
 WELDING MATERIAL CONTROLLER – FOR
WELDING MATERIAL CONTROLLER – FOR
RECEIVING, STORING, DRYING, KEEP WARM, RE-
RECEIVING, STORING, DRYING, KEEP WARM, RE-
DRYING AND ISSUING.
DRYING AND ISSUING.

5. CONTROL OF STORAGE
CONTROL OF STORAGE
 WELDING ELECTRODE - ORDERLY & SEPARATED WITH LABEL
WELDING ELECTRODE - ORDERLY & SEPARATED WITH LABEL
 STORED ACCORDING TO THE MANUFACTURER
STORED ACCORDING TO THE MANUFACTURER
RECOMMENDATION
RECOMMENDATION
 ELECTRODE PACKAGES SHALL NOT BE OPENED UNTILL IT IS
ELECTRODE PACKAGES SHALL NOT BE OPENED UNTILL IT IS
READY FOR DRYING
READY FOR DRYING
 ELECTRODE / FILLER RODS SHALL BE CLEARLY IDENTIFIED
ELECTRODE / FILLER RODS SHALL BE CLEARLY IDENTIFIED
WITH EITHER NATIONAL MATERIAL SPECIFICATION OR
WITH EITHER NATIONAL MATERIAL SPECIFICATION OR
MANUFACTURER’S BRAND DESIGNATION.
MANUFACTURER’S BRAND DESIGNATION.
ELECTRODE/FILLER WITH NO IDENTIFICATION SHALL NOT BE
ELECTRODE/FILLER WITH NO IDENTIFICATION SHALL NOT BE
USED
USED

6. CONTROL OF DRYING &
CONTROL OF DRYING &
KEEP WARMING
KEEP WARMING
 THIS SHALL BE CARRIED OUT BY WELDING
THIS SHALL BE CARRIED OUT BY WELDING
MATERIAL CONTROLLER
MATERIAL CONTROLLER
 BAKING AND KEEP WARMING AS PER
BAKING AND KEEP WARMING AS PER
SPECIFICATION OR MANUFACTURER
SPECIFICATION OR MANUFACTURER
RECOMMENDATION
RECOMMENDATION

7. CONTROL OF REQUEST &
CONTROL OF REQUEST &
ISSUING
ISSUING
 ONLY AUTHORIZED QC INSPECTOR & WELDING FOREMAN
ONLY AUTHORIZED QC INSPECTOR & WELDING FOREMAN
REGISTERED WITH SUBCON’S QC DEPARTMENT SHALL
REGISTERED WITH SUBCON’S QC DEPARTMENT SHALL
AUTHORIZED TO SIGN THE
AUTHORIZED TO SIGN THE WELDING REQUEST SLIP
WELDING REQUEST SLIP
 WELDING MATERIAL CONTROLLER SHALL NOT ISSUE ANY
WELDING MATERIAL CONTROLLER SHALL NOT ISSUE ANY
WELDING ELECTRODES/ FILLERS TO WELDER WITHOUT ANY
WELDING ELECTRODES/ FILLERS TO WELDER WITHOUT ANY
APPROVED WELDING REQUEST SLIP.
APPROVED WELDING REQUEST SLIP.
 ALL RECORDS OF THE REQUESTING & ISSUING OF WELDING
ALL RECORDS OF THE REQUESTING & ISSUING OF WELDING
ELECTRODES / FILLERS SHALL BE FILLED AND MAINTAINED
ELECTRODES / FILLERS SHALL BE FILLED AND MAINTAINED

8. CONTROL OF REQUEST &
CONTROL OF REQUEST &
ISSUING
ISSUING
 WELDING ELECTRODE SHALL ONLY BE ISSUED TO
WELDING ELECTRODE SHALL ONLY BE ISSUED TO
WELDER WITH A WORKING QUIVER (FOR STORAGE
WELDER WITH A WORKING QUIVER (FOR STORAGE
& WARMING)
& WARMING)
 EACH ISSUE SHALL BE LIMITED TO 3 KG PER EACH
EACH ISSUE SHALL BE LIMITED TO 3 KG PER EACH
QUIVER. ONE QUIVER IS ALLOWED TO CONTAIN
QUIVER. ONE QUIVER IS ALLOWED TO CONTAIN
ONLY ONE TYPE OF ELECTRODE
ONLY ONE TYPE OF ELECTRODE

9. CONTROL OF REQUEST &
CONTROL OF REQUEST &
ISSUING
ISSUING
 MATERIAL CONTROLLER SHALL CHECK THE
MATERIAL CONTROLLER SHALL CHECK THE
WELDING MATERIAL REQUEST FORMS FOR
WELDING MATERIAL REQUEST FORMS FOR
QUANTITY & TYPE OF WELDING MATERIAL BEFORE
QUANTITY & TYPE OF WELDING MATERIAL BEFORE
ISSUING
ISSUING
 ELECTRODE THAT HAVE BEEN RE-DRIED SHALL BE
ELECTRODE THAT HAVE BEEN RE-DRIED SHALL BE
ISSUED FIRST
ISSUED FIRST

10. CONTROL OF RETURN OF
CONTROL OF RETURN OF
WELDING MATERIAL
WELDING MATERIAL
 WELDING FOREMAN SHALL ENSURE ALL QUIVER & UNUSED
WELDING FOREMAN SHALL ENSURE ALL QUIVER & UNUSED
ELECTRODE / FILLER RODS TO BE RETURNED TO THE
ELECTRODE / FILLER RODS TO BE RETURNED TO THE
WELDING MATERIAL STORAGE AREA AT THE END OF THE
WELDING MATERIAL STORAGE AREA AT THE END OF THE
DAY
DAY
 WELDING MATERIAL CONTROLLER SHALL SEPARATE
WELDING MATERIAL CONTROLLER SHALL SEPARATE
UNUSED ELECTRODE FOR RE-DRIED OR DISPOSAL AS
UNUSED ELECTRODE FOR RE-DRIED OR DISPOSAL AS
REQUIRED
REQUIRED
 ELECTRODE SHALL NOT BE RE-DRIED MORE THAN ONCE.
ELECTRODE SHALL NOT BE RE-DRIED MORE THAN ONCE.
AFTER THE SECOND RE-DRIED, THE LEFT OVER WILL BE
AFTER THE SECOND RE-DRIED, THE LEFT OVER WILL BE
DISPOSED
DISPOSED

11. WELDING CONSUMABLE
WELDING CONSUMABLE
REQUEST SLIP
REQUEST SLIP
WELDING CONSUMABLE REQUEST SLIP
WELDING CONSUMABLE REQUEST SLIP
Welder no / Name
Welder no / Name /
/
Type of electrode / size
Type of electrode / size /
/
Type of filler rod / size
Type of filler rod / size /
/
Drawing no/Line no
Drawing no/Line no
Approved by
Approved by
Name / Signature
Name / Signature

12. WELDING CONSUMABLE
WELDING CONSUMABLE
CONTROL LOG SHEET
CONTROL LOG SHEET
WELDING CONSUMABLE CONTROL LOG SHEET
WELDING CONSUMABLE CONTROL LOG SHEET
Item
Item Date
Date Electrode
Electrode Electrode
Electrode Electrode
Electrode Baking Time
Baking Time
Re-baking
Re-baking
Time
Time Baking /
Baking /
Material
Material
Controller
Controller
Brand
Brand Batch No
Batch No Size
Size Start
Start End
End Start
Start End
End Temperature
Temperature Name/Sign
Name/Sign

13. WELDING CONSUMABLE
WELDING CONSUMABLE
ISSUING LOG SHEET
ISSUING LOG SHEET
WELDING CONSUMABLE ISSUING LOG SHEET
WELDING CONSUMABLE ISSUING LOG SHEET
Item
Item Welder No
Welder No Electrode Type
Electrode Type Size
Size Qty
Qty Time
Time Issued By
Issued By
Received
Received
By
By
Issue
Issue Return
Return Name/Sign
Name/Sign Name/Sign
Name/Sign

14. PROPER / GOOD CONTROL
PROPER / GOOD CONTROL
OF WELDING CONSUMABLE
OF WELDING CONSUMABLE
• ACHIEVED OF HIGH QUALITY
ACHIEVED OF HIGH QUALITY
WELDING
WELDING
• SAFE OPERATING PLANT
SAFE OPERATING PLANT

15. THANK YOU
THANK YOU