UBF MAINTENANCE SDN. BHD.

(347466-V)
Lot 4077, Kawasan Perindustrian Telok Kalong,
24007 Kemaman, Terengganu.
Tel : 09-8633888 (3 Line) Fax : 09-8633889

PROCEDURE
FOR
APPROVAL

JOB TITLE

GENERIC REPAIR PROCEDURE FOR

GRINDING AND BUILD-UP

LOCATION

PETRONAS PENAPISAN TERENGGANU,

KERTEH INDUSTRIAL AREA,
KERTEH, KEMAMAN,
TERENGGANU DARUL IMAN.

CLIENT

PETRONAS PENAPISAN (T) SDN BHD

DATE

REV

DATE

14/04/2005

PREPARED BY

REVIEWED BY

REVIEWED BY

APPROVED BY

(UBFMSB)

(UBFMSB)

(PPTSB)

(JKKP)

GENERIC
REPAIR PROCEDURE
FOR
GRINDING AND
BUILD-UP

UBF MAINTENANCE
SDN. BHD.

DOCUMENT NO.

REV

: 0

PAGE

TABLE OF CONTENT
1.0

REPAIR PROCEDURE

2.0

PURPOSE

3.0

SPECIFICATION

4.0

APPLICATION CODE / STANDARD

5.0

SEQUENCE OF WORK

6.0

SAFETY

7.0

REFERENCE & OTHER SUPPORTIVE DOCUMENT

GENERIC
REPAIR PROCEDURE
FOR
GRINDING AND
BUILD-UP

UBF MAINTENANCE
SDN. BHD.

DOCUMENT NO.

REV

: 0

PAGE

REPAIR PROCEDURE
1.0

INTRODUCTION
This repair procedure is required for Grind-off and perform Weld build-up (Weld Repair) on minor defect
such as Pitting Corrosion, Cluster Porosity, Under Cut, Pin Hole, Side wall Fusion and etc which have
been found during final inspection as per SOE.

2.0

PURPOSE
The purpose of this work as follow :
2.1 To grind-off all the defect (pitting, pinhole etc) at the defect area and carry-out Dye Penetration
Test (DPT). Stainless Steel material shall be used for Stainless Steel grinding disc.
2.2 To perform Build-up welding and carry-out Dye Penetration Test (DPT).

3.0

SPECIFICATION
- As per PPTSB requirement / Inspection report
- Detail Repair Specification data as in table attachment

4.0

APPLICABLE CODE / STANDARD

The welding and NDT works are to be carried out and in accordance with the follow:

5.0

4.1

ASME VIII DIV 1

- UW-42 " Surface Weld Metal Build-up "

4.2

ASME V

- Appendix 8 " Method for Liquid Penetrating Testing "

4.3

ASME IX

- Welding and Brazing Qualification

SEQUENCE OF WORK
5.1

Grinding Work
5.1.1 Prior to remove the defect, all piping/line that connect to the vessel shall suitably blank
off, isolated by spades, reverse spectacle blind and etc.
5.1.2 Open manhole and run air mover for gas removal and air circulation inside the vessel.
5.1.3 Mark the Defect area to grind off accordingly by appointed Third Party Inspection.
5.1.4 Grind off the defect until meet the sound metal and perform DPT to confirm the defect
has been removed from the respective shell area for welding surface preparation.

UBF MAINTENANCE
SDN. BHD.

5.2

GENERIC
REPAIR PROCEDURE
FOR
GRINDING AND
BUILD-UP

DOCUMENT NO.

REV

: 0

PAGE

Welding Work
5.2.1 Perform surface preparation before performing Weld build-up.
5.2.2 Ensure that area is free from Oil, Grease, Water or any other foreign material.
5.2.3 Proceed Weld build-up by DOSH qualified welder.
WPS No. : As per requirement Refer to Welding Qualification.
5.2.4 Perform Dye Penetration Test (DPT) upon completion of Weld build-up on the first layer.
5.2.5 If the result Dye Penetration Test (DPT) is unacceptable, remove the defect by grinding
and repeat Dye Penetration Test (DPT) to ensure it is completely removed.
5.2.6 If the result of Dye Penetration Test (DPT) is acceptable, proceed to Weld build-up on the
second layer using the same consumable as the first layer.
5.2.7 Repeat step 5.2.4 and 5.2.6 until the final layer.
5.2.8 Carry-out visual inspection and perform the Dye Penetration Test (DPT) to ensure
the weldment are free from any indication/defect.
5.2.9 After completion of all required testing and accepted, proceed with next action.
(Housekeeping, box-up, remove blind & demobilization)

6.0

7.0

SAFETY
6.1

All condition stated on pre task analysis (PTA) must complied with PTW

6.2

All personnel working on the job site shall be informed of the safety awareness by attending
the safety induction conducted by PPTSB representative prior to commencing work.

6.3

Full PPE in ensured whilst working at site.

6.4

Refer to Safety Operating Procedure for details.

REFERENCES & OTHER SUPPORTIVE DOCUMENT

i-

INSPECTION REPORT BY INSPECTION DEPARTMENT

ii-

WPS & PQR BY CONTRACTOR (UBF MAINTENANCE SDN. BHD.)

iii-

WQT BY CONTRACTOR (UBF MAINTENANCE SDN. BHD.)

iv-

ATTACHMENT DRAWING BY INSPECTION DEPARTMENT

v-

SAFE OPERATING PROCEDURE

UBF MAINTENANCE
SDN. BHD.

GENERIC
REPAIR PROCEDURE
FOR
GRINDING AND
BUILD-UP

DOCUMENT NO.

REV

: 0

PAGE

SAFE OPERATING PROCEDURE

1.0

INTRODUCTION
This procedure serves as guidelines on health and safety requirements to all personal involved in this
work. This is the minimum requirement of the safety operation procedure, please refer the operating
procedure provided by operation unit where applicable.

2.0

SEQUENCE OF WORK
2.1

Confined Space Entry and Manhole Opening ( For Repair inside CSE )
2.1.1 Supervisor / foreman must ensure that the work can only be started when no more hazardous
gases detected around the work and covered by approved permit.
2.1.2 Blinding all fuel steam or chemical lines to the vessel prior to manhole opening and running
of air mover continuously (after opening).
2.1.3 Use low-power internal lighting inside the vessel for clearer vision.
2.1.4 Standby safety watcher or attendance at the manhole during CSE
2.1.5 Supervisor must be observe the maximum allowable numbers of personnel to enter confined
space stated in the confine space permit.
2.1.6 Leave the safety pass at the manhole before enter the confined space.
2.1.7 Dark glass not allowed during CSE.

2.2

Grinding Work
2.2.1 Prior to blinding, client must verify and approved the blinding checklist.

UBF MAINTENANCE
SDN. BHD.

GENERIC
REPAIR PROCEDURE
FOR
GRINDING AND
BUILD-UP

DOCUMENT NO.

REV

: 0

PAGE

UBF MAINTENANCE SDN. BHD. (347466-V)

Lot 4077, Kawasan Perindustrian Telok Kalong,
24007 Kemaman, Terengganu.
Tel : 09-8633888 (3 Line) Fax : 09-8633889

REPAIR SPECIFICATION
EQUIPMENT NO.

PMT NO.

PLANT / LOCATION

DEFECT LOCATION

TYPE OF DEFECT

MATERIAL & WELDING SPECIFICATION

MATERIAL

THICKNESS

WELDING PROCESS FILLER METAL

SHELL
CHANNEL HEAD

NDT TO APPLY

BEFORE REPAIR
AFTER REPAIR

WPS NO.

WELDER NAME

WELDER ID

:
:

PREPARED BY UBFMSB :

REVIEWED BY PPTSB :

NAME :
DATE :

NAME :
DATE :

APPROVED BY DOSH :

NAME :
DATE :