CONSUMABLE STORAGE AND HANDLING PROCEDURE

PROCEDURE FOR WELDING CONSUMABLE STORAGE & HANDLING

1.   SCOPE:

·        This procedure covers the method for storage & handling conditions for special metal welding consumables.

2.   PURPOSE:

·        Purpose of this procedure is to lay down the system for handling of welding consumables and their proper storage.

3.   RESPONSIBILITIES:

·        Store manager & Production manager are responsible to control the system.

·        Store manager is control at his end in store for storage of welding consumables, and production manager is control the consumables after receiving from store and both manager maintain their record.

4.   METHOD (SMAW ELECTRODE)

·        The flux covering on SMAW electrodes is hydroscopic or moisture absorbing. The amount of moisture absorbed is dependent on atmospheric conditions of temperature & humidity.

·        After the packing of electrodes is opened the amount of moisture which is absorbed increases with the time of exposure.

·        Store manager should put all the remaining electrodes after giving some electrodes to manufacturing into mother oven which is situated into the store.

·        During manufacturing process SMAW electrodes which are directly taken from mother oven/packed box can take required electrodes directly for welding and other electrodes should kept into portable oven that also maintaining same temperature like mother oven.

MOTHER OVEN

PORTABLE OVEN

·        Electrodes which absorbed excessive moisture should be re-baked in a vented oven at 600°F ± 25°F (315°C ± 15°C) for 1 hour or 260°C ± 15°C for 2 hours.

·        Electrodes should not be stacked more than 6 layers deep within the oven.

·        Most electrodes can be re-bake at least 2-3 times without substantially affecting both the integrity of flux coating and their welding performance.

·        A common problem that may occur is the uneven absorption of moisture by the electrodes. For example: electrodes exposed overnight may exhibit ‘finger nailing’ (uneven burn off on one side of the electrode) problems during welding when use on the next day.

·        During the welding process the welders and supervisors shall collect all the used welding electrodes in the bin and end of the shift same shall be stored in the scrap material store.

·        Production supervisor should make a traceability of for all consumables that are used for the given projects.

·        Traceability contains:

-         Consumable batch number,

-         Quantity received date wise,

-         Welder name who borrow this consumables with his WPS number,

-         Baking temperature & time while received from store,

-         Re-baking in shop floor if required, temperature and time in portable oven,

-         Number of electrodes used for any project for cost evaluation (if required).

·        All ovens should be periodically calibrated.