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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
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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 recipients organization. None of the information
contained in this document shall be disclosed outside the recipients own organization
without the prior written permission of BP Group, unless the terms of such agreement or
contract expressly allow.
31 October 2007 GIS 18-012
Storage and Control of Welding Consumables
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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

31 October 2007 GIS 18-012
Storage and Control of Welding Consumables
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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.
31 October 2007 GIS 18-012
Storage and Control of Welding Consumables
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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 fabricators 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
31 October 2007 GIS 18-012
Storage and Control of Welding Consumables
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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
31 October 2007 GIS 18-012
Storage and Control of Welding Consumables
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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 fabricators quality assurance procedures.
5.2. Procedure checklist
A fabricators 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
fabricators 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 20-30C (68-86F). 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 fabricators 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:
31 October 2007 GIS 18-012
Storage and Control of Welding Consumables
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1. Subjected to any drying treatment,
2. Exposed to temperatures greater than either 50C (122F) 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 fabricators
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 manufacturers 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 fabricators welding engineer shall issue drying instructions based on the
manufacturers 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 fabricators welding engineer shall issue procedures concerning the control and usage
of SAW fluxes based on the manufacturers recommendations.
1. SAW flux shall only be recycled in accordance with the manufacturers
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 fabricators 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.
31 October 2007 GIS 18-012
Storage and Control of Welding Consumables
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1. Cellulosic and other non hydrogen controlled SMAW electrodes shall be issued in the
manufacturers packaging or in a dry and appropriately labelled quiver.
2. Vacuum packed SMAW hydrogen controlled electrodes shall be issued in the
manufacturers 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, 70-100C (158-212F). The quiver shall be
appropriately labelled.
4. GTAW welding wire should be issued in either the manufacturers 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 manufacturers 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 manufacturers
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 fabricators welding supervisory staff.
31 October 2007 GIS 18-012
Storage and Control of Welding Consumables
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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
31 October 2007 GIS 18-012
Storage and Control of Welding Consumables
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Bibliography
[1] GP 50-01 Application of Criticality Ratings (RP 50-1).