GS 118-4

STORAGE AND CONTROL OF

WELDING CONSUMABLES
August 1997

Copyright The British Petroleum Company p.l.c.

Copyright The British Petroleum Company p.l.c.

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 organisation. None of the information contained in this document shall be
disclosed outside the recipient's own organisation without the prior written permission of
Manager, Standards, BP International Limited, unless the terms of such agreement or
contract expressly allow.

BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING

Issue Date
Doc. No.

GS 118-4

August 1997

Latest Amendment Date

Document Title

STORAGE AND CONTROL OF WELDING

CONSUMABLES
(Replaces BP Std 165)

APPLICABILITY
Regional Applicability:

International

SCOPE AND PURPOSE

This specification specifies BP general requirements for the receipt, storage and control of
welding consumables held under shop and site conditions and has two principal objectives:
a)

The provision of a high degree of assurance that the specified consumables are
employed in any given joint.

b)

The prevention of damage or deterioration of the consumables at all stages from receipt
through to welding.

AMENDMENTS
Amd
Date
Pages
Description
_________________________________________________

CUSTODIAN (See Quarterly Status List for Contact)

Materials and Inspection

Issued by:-

Engineering Practices Group, BP International Limited, Research & Engineering Centre

Chertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOM
Tel: +44 1932 76 4067
Fax: +44 1932 76 4077
Telex: 296041

CONTENTS
Section

Page

FOREWORD ...................................................................................................................... ii
1. INTRODUCTION............................................................................................................1
1.1 Scope and Purpose .....................................................................................................1
2. GENERAL .......................................................................................................................1
2.1 Application of this Specification..................................................................................1
2.2 Storage and Control ...................................................................................................1
3. QUALITY ASSURANCE ................................................................................................2
3.1 Procedures .................................................................................................................2
4. CONSUMABLE STORAGE AND CONTROL .............................................................2
4.1 Basic Requirements ....................................................................................................2
4.2 Detailed Procedures....................................................................................................3
4.3 Procedure Checklist....................................................................................................4
5. Supporting Facilities ........................................................................................................6
5.1 Supporting Staff .........................................................................................................6
5.2 Support Services ........................................................................................................6
FIGURE 1 ............................................................................................................................7
FLOW CHART FOR TYPICAL CONSUMABLE CONTROL PROCEDURE ................7
APPENDIX A.......................................................................................................................8
DEFINITIONS AND ABBREVIATIONS .......................................................................8
APPENDIX B.......................................................................................................................9
LIST OF REFERENCED DOCUMENTS........................................................................9

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

PAGE i

FOREWORD
Introduction to BP Group Recommended Practices and Specifications for Engineering
The Introductory Volume contains a series of documents that provide an introduction to the
BP Group Recommended Practices and Specifications for Engineering (RPSEs). In particular,
the 'General Foreword' sets out the philosophy of the RPSEs. Other documents in the
Introductory Volume provide general guidance on using the RPSEs and background
information to Engineering Standards in BP. There are also recommendations for specific
definitions and requirements.
Value of this Guidance for Specification
This Guidance for Specification provides the fabricator with guidelines which indicate the
anticipated contents of the fabricators welding consumable control procedures.
Application
This Guidance for Specification is intended to guide the purchaser in controlling the welding
activity in a manner that reduces the likelihood of problems arising from the application of
incorrect or unsuitable welding consumables.
Any text in italics is Commentary. The Commentary provides background information which
supports the requirements of the Specification, and may discuss alternative options.
This document may refer to certain local, national or international regulations but the
responsibility to ensure compliance with legislation and any other statutory requirements lies
with the user. The user should adapt or supplement this document to ensure compliance for
the specific application.
Principal Changes from Previous Edition
This edition of BP Group GS 118-4, formerly BP Std. 165, has been amended to reflect
current expectation with regard to custom and practice within the fabrication industry. The
amendments are general in nature and do not consist of any major technical changes.
Feedback and Further Information
Users are invited to feed back any comments and to detail experiences in the application of
BP RPSE's, to assist in the process of their continuous improvement.
For feedback and further information, please contact Standards Group, BP International or the
Custodian. See Quarterly Status List for contacts.

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

PAGE ii

1.

INTRODUCTION
1.1

Scope and Purpose

This specification defines the general BP requirements for the receipt,
storage and control of welding consumables held under shop and site
conditions and has two principal objectives:
a)

The provision of a high degree of assurance that the specified

consumables are employed in any given joint.

b)

The prevention of damage or deterioration of the consumables

at all stages from receipt through to welding.

This specification applies to all fabrications where a design code is used,

and is not restricted to pressure containing components. The principles
outlined apply to all welded fabrications.
This specification will not be used to impose additional constraints on
existing procedures which embody the principles of storage and control
outlined.
2.

GENERAL
2.1

Application of this Specification

The application of this specification is self-limiting by the number of
welding consumable types used, i.e. the fewer, the simpler the control
system required.

2.2

Storage and Control

Weld metal composition is generally controlled within specific limits to
achieve the required levels of strength, toughness or corrosion
resistance. Since a variety of consumables may be in use at any given
manufacturing location, strict control shall be exercised to prevent loss
of identification or the use of incorrect weld metal.
The control of welding consumables shall be in accordance with fully
documented procedures.
All welding consumables shall be stored such as to prevent damage or
deterioration or loss of identity.

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

PAGE 1

3.

QUALITY ASSURANCE
3.1

Procedures
A fabricator's welding consumable control procedures shall form an
integral part of a quality system based on IS0 9002 or an equivalent
document approved by BP.
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 define the personnel responsible for the efficient
operation of the consumable control procedures at management and
shop floor supervisory level.
Copies of the procedures shall be readily available and referenced in the
fabricator's quality plan.
The implementation of procedures will be audited as necessary by BP
or its authorised representative during the fabrication programme. BP
shall be advised of the corrective actions taken by the fabricator as a
result of any Non Conformance Reports issued by any such audit.

4.

CONSUMABLE STORAGE AND CONTROL

4.1

Basic Requirements
Written procedures are a pre-requisite for any control system. Potential
problems with the practicalities of consumable control may be
minimised by applying the following principles.
a)

All welding consumables shall meet the requirements of the

welding procedure specifications and have been manufactured
to an internationally accepted standard.

b)

The number of different welding consumables in use on a

particular fabrication or in a specific fabrication area should be
minimised.

c)

All welding consumables should be marked or colour-coded for

easy recognition. Colour coding should be to a system
developed by the fabricator and agreed with BP.

d)

All materials should be segregated during fabrication. Thus,

specific areas for the fabrication of carbon, low-alloy or stainless
steels should be established.

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

PAGE 2

Where various grades of carbon steel, such as those for normal

ambient and low temperature duties, are fabricated
simultaneously, they should also be segregated.
e)

f)

4.2

All welding consumables shall be stored indoors in specific

storage areas.
-

Non-hygroscopic electrodes and fluxes shall be stored in

labelled containers in the storage areas.

Hygroscopic electrodes and fluxes shall be stored in

hermetically sealed containers or in heated holding ovens
once the containers have been opened.

Drying of hygroscopic electrodes and fluxes in heated

drying ovens to achieve the required hydrogen levels
shall be in accordance with the manufacturer's
instructions. These instructions shall form part of the
Quality Assurance system and be available for use of the
supervisor responsible.

Hydrogen controlled electrodes which have been dried to

achieve specific hydrogen levels in weld metal, as required by
some design codes, or which were originally supplied in
hermetically sealed vacuum packed containers shall not be redried unless such a treatment is specifically recommended by the
consumable manufacturer. Electrodes of either of these types
which are returned to the electrode store and are not re-dried
shall be removed from the BP worksite.

Detailed Procedures
A fabricator's consumable control procedure should be established to
suit his own specific operations. However, all consumable control
procedures should conform to the checklist in 4.3. This covers the
principal points that would be found in an acceptable system 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.

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

PAGE 3

4.3

Procedure Checklist

4.3.1

Preference should be given to manufacturers supplying premarked and

clearly identified products with covered electrodes and straight lengths
of wire individually identified. This requirement is met by consumables
manufactured to ASME Section II, Part C except that straight lengths
of wire are not required to be marked by that standard.

4.3.2

Where unmarked electrodes or wire lengths are purchased, each

consumable shall be marked at one end in accordance with an
identification system established by the fabricator. Marking shall take
place under the control of the fabricator's welding supervisory staff,
immediately the packaging seal is broken.

4.3.3

On receipt, all welding consumables shall be held in a quarantine area

until compliance with the purchase order has been verified, full details
(including supplier, manufacturer, brand name, batch number, quantity
received and delivery date) recorded and certificates filed. BP
requirements shall be given in the schedule of documentation
requirements. Any further checks required shall be undertaken before
the consumables are transferred to the storage area. The storage area
shall be dry, i.e. continually maintained with a relative humidity equal to
or less than 60%, and at a minimum temperature of 20C.

4.3.4

Consumables shall be transferred to the workshop or other secondary

storage areas only as they are required for use. 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. All secondary storage areas shall be maintained dry and
warm as required in 4.3.3.

4.3.5

It is the fabricator's responsibility to ensure that all hydrogen-controlled

consumables produce the weld metal hydrogen level required by the
fabrication specification.
The fabricator's welding supervisory staff shall issue drying instructions
based on the manufacturer's recommendations for all submerged arc
fluxes and SMAW electrodes as required.

4.3.6

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 and
calibrated regularly.

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

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4.3.7

Ovens should not be overloaded. Where oven shelves are loaded with
electrodes more than three layers deep, the control thermocouple
should be placed between the layers to ensure that electrodes at the
centre of the burden receive the correct thermal cycle.

4.3.8

Each type and size of consumable shall be clearly marked and

segregated within the drying and storage (holding) ovens.
The contents of each oven shall be clearly marked on the door.

4.3.9

Manual 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 when appropriate,
consumable type and quantity required for the work period, i.e. one
shift maximum. Electrodes shall be issued directly into special
containers or, in the case of hydrogen-controlled electrodes, quivers
heated to 70C to 100C.
Where the usage of manual electrodes is low, or the location of the
work is unsuitable for the use of heated quivers, consideration should
be given to the use of hermetically sealed, vacuum packed, low
hydrogen electrodes. However, it remains the fabricator's responsibility
to ensure that the moisture level in such consumables remains within
acceptable limits.

4.3.10

In the case of submerged arc and other semi-automatic or mechanised

welding processes, the welding operator shall present a machine card
when drawing consumables. This card shall be endorsed by the
fabricator's welding supervisory staff and specify all relevant details as
required on the work card above.

4.3.11

Only consumables for one welding procedure shall be issued to a welder

or welding operator at any given time, and a record of all consumables
issued shall be maintained in the secondary storage area.

4.3.12

All manual consumables remaining at the end of a work period shall be

returned to the store. All returns shall be recorded and put into holding
ovens or, if necessary, re-dried in accordance with the manufacturer's
recommendations prior to re-issue. However, hydrogen controlled
electrodes which have been dried to achieve specific hydrogen levels in
weld metal as required by some design codes shall not be re-dried and
shall be removed from the BP worksite.
Part used or stub ends of electrodes and wire shall be collected at the
end of each shift or on completion of the job, whichever is sooner and
deposited in scrap bins.

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STORAGE AND CONTROL OF WELDING
CONSUMABLES

PAGE 5

5.

4.3.13

Procedures shall be in force which prevent deterioration of submerged

arc welding fluxes when the machines are not in use. Submerged arc
fluxes shall be recovered and recycled in accordance with the
manufacturer's instructions.

4.3.14

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.

4.3.15

All records concerned with consumable control, including all

work/machine cards and stores records, shall be audited as a matter of
routine by the fabricator's quality control staff.

Supporting Facilities
5.1

Supporting Staff
Welding supervisory staff, such as welding engineers, foremen and
storemen, are generally required to ensure the continuity of a
fabricators welding operations. While such personnel may provide
feedback on the effectiveness of consumable control procedures, one
member of the Quality Control staff should have specific responsibility
for monitoring these procedures.

5.2

Support Services
For specialised welding activities, it is recommended that the fabricator
has access to basic metallographic and portable analytical equipment to
confirm the effectiveness of the consumable control procedures. Such
techniques are particularly valuable in the fabrication of highly alloyed
or exotic materials, the deposition of weld overlays and the production
of equipment and piping for low temperature applications.

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

PAGE 6

Transfer
Quarantine

Transfer

Primary
Storage
Transfer
Request

Verify

Welding
Supervisory
Staff

Secondary
Storage

Drying

Issue

Holding

Return

Consumable Consumables
Requisition
Work Card
&
Consumable
Requisition

Unused
Consum
-ables

Welder
Release

Release

Quality Control

Fabrication
Verify
Damaged
or
unidentified
consumables

Stub ends
or
partially
used
consumables

REMOVE
FROM WORKSITE

FIGURE 1
FLOW CHART FOR TYPICAL CONSUMABLE CONTROL PROCEDURE

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

PAGE 7

APPENDIX A
DEFINITIONS AND ABBREVIATIONS
Definitions
Standardised definitions may be found in the BP Group RPSEs Introductory volume.
Abbreviations
ANSI
API
ASME
BS
BSI
SMAW

American National Standards Institute

American Petroleum Institute
American Society of Mechanical Engineers
British Standard
British Standards Institute
Shielded Metal Arc Welding

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

PAGE 8

APPENDIX B
LIST OF REFERENCED DOCUMENTS
A reference invokes the latest published issue or amendment unless stated otherwise.
Referenced standards may be replaced by equivalent standards that are internationally or
otherwise recognised provided that it can be shown to the satisfaction of the purchaser's
professional engineer that they meet or exceed the requirements of the referenced standards.
Note:

This is a list of Codes and Standards referred to in this BP Guidance for

Specification. Any reference to these documents invokes the latest published issue
or amendment.

International Standards
ISO 9002

Quality Systems - Model for Quality Assurance in Production and Installation

American Standards
ASME

Boiler and Pressure Vessel Code Section II Material Specifications - Part C

Welding Rods, Electrodes and Filler Metals.

GS 118-4
STORAGE AND CONTROL OF WELDING
CONSUMABLES

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