GIS 18 012 31 October 2007

GIS 18-012

Storage and Control of Welding Consumables

Group Instruction for Supply

Document No. GIS 18-012

Applicability Group

Date 31 October 2007

BP GROUP ENGINEERING TECHNICAL PRACTICES

31 October 2007 GIS 18-012 Storage and Control of Welding Consumables

Downloaded Date: 6/17/2008 10:27:31 PM The latest update of this document is located in the BP ETP and Projects Library

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Foreword

This is the first issue of Engineering Technical Practice (ETP) BP GIS 18-012. This Group Instruction for Supply (GIS) is a republication of GP 18-02 and is based on the BP heritage GS 118-4. BP Group Standards (GHSER, Integrity Management Functional Standard, etc.) dictate requirements that must be satisfied in addition to the requirements of this document.

BP Exploration and Operating Company has prepared this GIS. It defines the requirements of BP for the storage and control of welding consumables. Whilst this document is not based on any specific standard it should be utilised for all work involving welded construction. It should be used to supplement individual project fabrication specifications and other BP GP/GIS (Group Practice/Group Instruction for Supply) documents related to welded construction.

The fundamental requirement of BP is that appropriate welding consumables should be used for all welded constructions and that these consumables should be maintained in pristine condition until required for welding.

Copyright 2007, BP Group. All rights reserved. The information contained in this document is subject to the terms and conditions of the agreement or contract under which the document was supplied to the recipient’s organization. None of the information contained in this document shall be disclosed outside the recipient’s own organization without the prior written permission of BP Group, unless the terms of such agreement or contract expressly allow.



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Table of Contents

Page

Foreword ........................................................................................................................................ 2

1. Scope .................................................................................................................................... 4

2. Normative references............................................................................................................. 4

3. Symbols and abbreviations .................................................................................................... 5

4. Quality assurance .................................................................................................................. 5

5. Consumable storage and control ........................................................................................... 5 5.1. Basic requirements ..................................................................................................... 5 5.2. Procedure checklist..................................................................................................... 7

Bibliography .................................................................................................................................. 11

List of Figures

Figure 1 - Example Flow Chart for Typical Consumable Control Procedure.................................. 10



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1. Scope

This GIS defines BP requirements for the receipt, storage, and control of welding consumables held under shop and site conditions. It is applicable to all welded construction. This GIS will be used to supplement individual project fabrication specifications and may be used in conjunction with any relevant design code. The principal objectives of this GIS are:

a. Prevention of damage or deterioration of welding consumables at all stages from receipt through to welding and,

b. Provision of a high level of assurance that the specified consumables are employed in the welding of any given joint.

This GIS will not be used to impose additional constraints on any existing procedures which embody the principles of storage and control outlined.

2. Normative references

The following normative documents contain requirements that, through reference in this text, constitute requirements of this technical practice. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. However, parties to agreements based on this technical practice are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the normative document referred to applies.

BP GIS 36-103 Positive Material Identification (PMI).

American Society of Mechanical Engineers (ASME) ASME Boiler and Pressure Vessel Code, Section II Materials, Part C. ASME SFA 5 series Specification for Welding Rods, Electrodes, and Filler Wires. ASME SFA 5.01 Filler Metal Procurement Guidelines.

American Welding Society (AWS) AWS A4.3 Standard Methods for Determination of the Diffusible Hydrogen Content

of Martensitic, Bainitic and Ferritic Steel Weld Metal Produced by Arc Welding.

AWS A5 series Specifications for Welding Rods, Electrodes, and Filler Wires. AWS A5.01 Filler Metal Procurement Guidelines.

European Standard (EN) EN 499 Welding consumables – Covered electrodes for manual metal arc welding

of non alloy and fine grain steels – Classification. EN 757 Welding consumables – Covered electrodes for manual metal arc welding

of high strength steels – Classification. EN 12070 Welding consumables – Wire electrodes, wire and rods for arc welding of

creep resisting steels – Classification. EN 12072 Welding consumables – Wire electrodes wires and rods for arc welding

of stainless and heat resisting steels – Classification. EN 12074 Welding consumables – Quality requirements for the manufacture, supply

and distribution of consumables for welding and allied processes.



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International Organisation for Standardisation (ISO) ISO 9001 Quality management systems. ISO 3690 Welding and allied processes - Determination of hydrogen content in

ferritic steel arc weld metal. ISO 14344 Welding and allied processes - Flux and gas shielded electrical welding

processes – Procurement guidelines for consumables. ISO 18274 Welding consumables – Solid wire, strips and rods for fusion welding of

nickel and nickel alloys – Classification.

3. Symbols and abbreviations

For the purpose of this GIS, the following symbols and abbreviations apply:

FCAW Flux cored arc welding.

GMAW Gas metal arc welding.

GTAW Gas tungsten arc welding.

RH Relative humidity

SAW Submerged arc welding.

SMAW Shielded metal arc welding.

4. Quality assurance

a. Fabricators shall operate a quality system based on IS0 9001 or an equivalent document approved by BP. Welding consumable control procedures shall form an integral part of the quality system.

b. Detailed written procedures shall be established for the systematic receipt, storage, issue, and control of welding consumables and the attendant recording of these actions. These procedures shall identify the quality control and welding supervisory personnel responsible for the efficient operation of the consumable control procedures.

c. The implementation and effectiveness of these procedures shall be routinely monitored by their inclusion in the fabricator’s internal audit schedule.

1. BP shall be apprised of the findings of these internal compliance audits, as well as any other audits performed by clients or by certification authorities during the BP contract period.

2. BP or its authorised representative will further audit the implementation of the procedures.

5. Consumable storage and control

5.1. Basic requirements

While adherence to documented procedures will ensure that few issues related to consumable storage and control arise during fabrication it is essential that a number of fundamental principles associated with the quality assurance of both consumables and welded fabrication are also followed. Potential problems with the



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practicalities of storage and consumable control as well as the subsequent welding operations may be minimised by the application of the following principles.

The following principles shall be implemented on welded fabrication activities for BP.

a. Welding consumables shall be purchased from manufactures operating a quality system based on ISO 9001 or EN 12074. Unless specifically agreed otherwise by BP welding consumables shall be manufactured to meet the test requirements of the relevant ISO/EN consumable standards (for example ISO 18274, EN 499, EN 757, EN 12535, EN 12070, or EN 12072), the ASME SFA 5 series or the AWS A5 series.

b. Unless specifically agreed otherwise by BP welding consumables shall be supplied in conformance with the ISO 14344/ASME SFA 5.01/AWS A5.01 lot classification as noted below and lot certification in accordance with ISO 14344 Schedule 5 or ASME SFA 5.01/ AWS A5.01 Schedule J.

1. SMAW electrodes shall be supplied in accordance with the requirements of lot classification Class C4 or Class C5.

2. Solid wires shall be supplied in accordance with the requirements of lot classification Class S3.

3. Flux cored or metal cored wires shall be supplied in accordance with the requirements of Class T3.

4. SAW flux shall be supplied in accordance with Class F2.

c. Carbon and ferritic steel welding consumables, except cellulosic SMAW electrodes, shall be supplied with certification stating the as deposited weld metal diffusible hydrogen level determined in accordance with ISO 3690 or AWS A4.3.

d. Welding consumables proposed for use on any given construction shall be qualified for use in accordance with the applicable BP project fabrication specification and the requirements of the relevant design code.

e. Welding consumables employed for the fabrication of the following structures shall be traceable to the relevant manufacturing lot certification:

1. Structural steel: Primary structure, including attachments, for both offshore and onshore construction.

2. Pipelines: Girth welds and any attachments to both offshore and onshore pipeline systems carrying hydrocarbons or other volatile or toxic substances.

3. Pipework and pressure vessels: Process pipework and pressure vessels categorised as Criticality 1 by BP.

Criticality should be determined in accordance with GP 50-01.

4. Storage facilities: Tankage used for the storage or holding of hydrocarbons or other volatile or toxic substances.

5. Other components as dictated by regulatory authorities, construction codes or project specifications.

f. The number of different welding consumables to be used on a particular fabrication or in a specific fabrication area shall be minimised. Additionally, consumables should be used on a lot by lot basis, a new lot only being utilised once supply from the initial lot has been exhausted.

g. Different materials (including parent metal components or materials as well as welding consumables) should be segregated during fabrication. Thus, specific areas should be established for the fabrication of carbon steels, low-alloy steels, stainless steels, nickel alloys, copper-nickel alloys, or titanium. In certain instances it may be necessary to further



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segregate specific grades of material, e.g. normal grades and low temperature grades of carbon steel, and, austenitic and duplex grades of stainless steels.

h. If the construction specification requires Positive Material Identification (GIS 36-103) to be employed during fabrication, deposited weld metals shall be included in the sampling routine agreed with BP.

i. Measuring devices and instruments required for the implementation of the consumable storage and control procedure shall be included in the list of equipment requiring regular calibration under the fabricator’s quality assurance procedures.

5.2. Procedure checklist

A fabricator’s consumable control procedure shall be established to suit his specific operations. However, consumable control procedures should as a minimum conform to the checklist detailed below. This checklist covers the principal points that would be expected to be found in a storage and control procedure acceptable to BP and will form the basis of any audit undertaken by BP.

A flow chart for a typical consumable control procedure is shown in Figure 1.

a. Welding consumables shall be supplied in clearly marked packaging. Each SMAW electrode, straight wire length, or consumable spool, shall be individually marked and identified by the manufacturer.

b. Exceptionally and if specifically agreed by BP, unmarked SMAW electrodes or straight wire lengths may be purchased. However, each SMAW electrode shall be marked at the stub end and each wire length shall be marked at both ends in accordance with an identification system as agreed by BP. Marking shall take place under the control of the fabricator’s welding supervisory staff, immediately after the packaging seal is broken.

c. If spooled consumables are cut into individual lengths for use as GTAW filler each individual length shall be clearly identified as required by �5.2.b.

d. On receipt, welding consumables shall be held in a weather protected quarantine area until compliance with the purchase order has been verified, full certification details (including supplier, manufacturer, brand name, lot number, quantity received and delivery date) have been recorded, and the certificates have been filed. Consumable deliveries shall be specifically examined for packaging damage. Any damage that has resulted in the perforation of vacuum or hermetically sealed packaging shall be cause for rejection.

e. Following receipt and inspection the consumables should be promptly transferred to the storage area. The storage area shall be dry, humidity controlled (equal to or less than 60%RH), and maintained at a temperature in the range of 20-30°C (68-86°F). Humidity and temperature shall be continuously recorded.

f. Consumables shall be transferred to the workshop or other secondary storage areas only as they are required for use.

1. This transfer shall take place at the request of the fabricator’s welding supervisory staff and full details of each transfer shall be recorded in both of the storage areas concerned.

2. In the case of vacuum or hermetically sealed packaging, the packaging shall again be inspected for damage on receipt at the workshop or secondary storage. Damaged seals shall be cause for rejection and the consumables shall be returned to the quarantine area.

3. Secondary storage areas shall be kept dry and warm as required in �5.2.e and the temperature and humidity shall be monitored and recorded continuously or at specified intervals.

g. In the case of cellulosic SMAW consumables the electrodes shall not be:



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1. Subjected to any drying treatment,

2. Exposed to temperatures greater than either 50°C (122°F) or the maximum recommended by the manufacturer,

3. Subjected to any form of uncontrolled or unapproved treatment.

h. If hydrogen-controlled SMAW electrodes are to be used for fabrication preference should be given to the use of vacuum packed consumables.

i. If vacuum packed hydrogen controlled SMAW consumables are employed, the fabricator’s welding engineer shall issue a procedure concerning the storage and handling of the consumables and the maximum time the consumables may be exposed to the atmosphere once the vacuum seal is broken.

1. This procedure shall be based on the manufacturer’s recommendations, and shall require the time of opening each packet to be recorded.

2. Any consumables either exceeding the agreed exposure time or remaining at the end of the work period shall be removed from the BP work site unless a specific re-drying cycle has been agreed by BP.

j. If hydrogen controlled SMAW consumables requiring drying prior to use are employed, the fabricator’s welding engineer shall issue drying instructions based on the manufacturer’s recommendations. Electrodes shall not be re-dried unless a specific re-drying cycle has been agreed by BP.

1. Drying and elevated temperature storage (holding) shall be performed in purpose-built, thermostatically-controlled ovens located within the secondary storage area. These ovens shall be fitted with a temperature indicator and should also be equipped with a temperature recorder.

2. Ovens shall not be overloaded and individual shelves shall contain no more than four layers of electrodes. If oven shelves are loaded with electrodes more than two layers deep the control thermocouple shall be placed between the layers.

Central placement of the control thermocouple ensures that the electrodes at the centre of the burden receive the correct drying cycle.

3. Each type and size of consumable shall be clearly marked and segregated within the drying and storage (holding) ovens.

4. The contents of each oven shall be clearly marked on the outside of the door.

Correct storage, drying, and handling of hydrogen-controlled consumables ensure that the maximum weld metal hydrogen level required by either the fabrication specification or the welding procedure is met.

k. The fabricator’s welding engineer shall issue procedures concerning the control and usage of SAW fluxes based on the manufacturer’s recommendations.

1. SAW flux shall only be recycled in accordance with the manufacturer’s recommendations and with the specific agreement of BP.

2. The procedure shall clearly state the measures required to prevent the deterioration of any SAW flux held in welding machine hoppers when the welding equipment is not in use , e.g. overnight and during weekends or longer term shut downs.

l. SMAW and manual GTAW welding consumables shall be issued to welders only on production of a work card endorsed by the fabricator’s welding supervisory staff on at least a daily basis. This card shall list full details of the job, including application and joint number, if appropriate, consumable type, and quantity required for the work period, i.e. one shift maximum.



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1. Cellulosic and other non hydrogen controlled SMAW electrodes shall be issued in the manufacturer’s packaging or in a dry and appropriately labelled quiver.

2. Vacuum packed SMAW hydrogen controlled electrodes shall be issued in the manufacturer’s packaging or in a dry and appropriately labelled quiver.

3. Fabricator dried SMAW hydrogen controlled electrodes shall be issued in quivers heated to, and subsequently maintained at, 70-100°C (158-212°F). The quiver shall be appropriately labelled.

4. GTAW welding wire should be issued in either the manufacturer’s container or in an appropriately labelled tubular plastic container.

m. In the case of spooled wire for GMAW, FCAW, SAW, or other semi-automatic or mechanised welding processes, the welding operator shall present a work card (as in �l above) when drawing consumables from storage.

n. When mounted on the welding machine, spooled wire consumables shall be covered to prevent contamination by weld spatter, dust, grease, or other substances.

o. Consumables for one welding procedure shall only be issued to a welder or welding operator at any given time and a record of consumables issued shall be maintained at the point of issue.

p. SMAW and manual GTAW consumables remaining at the end of a work period shall be returned to the store.

1. Returns shall be recorded and shelved.

2. SMAW electrodes shall be placed in holding ovens or if necessary, re-dried in accordance with the manufacturer’s recommendations prior to re-issue.

3. Hydrogen controlled SMAW electrodes shall not be re-dried unless a specific re-drying cycle has been agreed by BP.

q. Spooled welding consumables shall be returned to the store when the job for which they were issued is complete. Further, unless otherwise directed by the manufacturer’s recommendations, consumables shall also be returned to the store if the welding equipment will stand idle for more than 12 hours.

This is considered good practice for spooled wire consumables to prevent the deterioration of the wire surface quality by accumulation of dust and other air borne contaminants including moisture. Prolonged exposure to moist air can lead to rapid deterioration and surface rusting of C Mn and low alloy steel wires rendering them unsuitable for use. Cored wires may also be subject to moisture absorption resulting in an increase in weld metal hydrogen content and an associated increase in the risk of fabrication hydrogen cracking with C Mn and low alloy steel consumables.

r. Any non-identified, contaminated, or otherwise damaged consumables including those suspected of being damp, found in any storage or fabrication area shall be immediately destroyed under the control of the fabricator’s welding supervisory staff.



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Figure 1 - Example Flow Chart for Typical Consumable Control Procedure

Temperature and humidity records

Transfer Transfer Transfer Receipt of Materials Quarantine

Primary Storage

Welding Supervisory

Staff

Quality Control

Secondary Storage

Drying Holding

Issue Return

Fabrication

Local Storage e.g. Vac-pack

or quiver

Welder

Remove from

Worksite

Paperwork route

Consumable route

Verification of certification

Release

Verification of correct consumable usage

(certification or PMI)

Consumable requisition

Consumables Consumable requisition

Damaged or unidentified consumables

Consumable transfer requests

Self-contained controlled storage, drying and issuing area

Release

Shop floor record

Unused Consumables



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Bibliography

[1] GP 50-01 Application of Criticality Ratings (RP 50-1).

Documents

GIS 18 012 31 October 2007