BOON & CHEAH STEEL PIPES SDN. BHD.

WELD REPAIR PROCEDURE FOR CARBON STEEL

FORM-73

This procedure shall be referred when the unsound metal o weld defects are found of visual
examination, and or NDT methods.

I JOB NO.: LINE NO.:

II SPOOL NO.: JOINT NO.:
III TYPE OF WELD DEFECT(S):

Poor Contour Undercut Pinhole

Incomplete root penetration Concavity
Slag Inclusion Internal Porosity Lack of fusion
Crack Excess penetration Others

* Tick appropriately
The above had been confirmed by:__________________

* Vis. Exam D.P.I. M.P.I R.T U.T

SKETCH:

The defective weld shall be repaired in accordance with the aprpoved W.P.S. No. (_______)
 Rev. 2

(Rev. 1 Ref

WELD REPAIR PROCEDURE

(CARBON STEEL)

1.0 SCOPE

This is a method statement defining all the necessary steps leading up to the completion of a
weld repair for Carbon Steel piping only.

2.0 REFERENCES

No 1
No 2
No 3

3.0 PROCEDURE

3.1 Identification and marking.

3.3.1 It is the responsibility of the NDT Coordinator to give the Repair Crew accurate and
complete information regarding the type, location and depth defect(s). The information
will include the following:

a) Request for weld repair RWR (sample attached).

b) Tracing of repair area from the radiograph.
c) Markings on the pipe surface showing the repair are. The repair Crew should
remove either side of the indicated repair area a minimum of 25 mm to ensure
complete removal of the defects.

3.2 Root Repairs.

3.2.1 Root repairs shall be done from inside the pipe wherever there is access by
backwelding.

In such cases, for safety purposes, adequate ventilation will be provided inside piping
during the repair welding a responsible person will be on stand by during this period.
If no access will be available to the inside, than the welding will be ground from the
outside using 4’’ grinder with 3 disc. To cut open the root for the removal of defect(s).

The root gap repair and configuration of the ground repair area will, as far as
practicable, be the same as the WPS requirements.

3.2.2 Welding should proceed as per the approved Welding Procedures Specification.

3.2.3 In case of cracks, after grinding, the area will be DP/MPI tested to ensure complete
removal of the crack prior to reweld.

Linear defects and porosities open to surface and subsurface can be detected by
penetrant test and magnetic Particle Testing methods.
 Defects noted for repair during Radiographic Inspection will be re-radiographed after
repair for final acceptance and record.

Penetrant test and Magnetic Particle Tests will be done to ensure the correct method of
removal or defects by grinding.

3.3 Repairs above the roof.

3.3.1 In such repairs, grinding can be done using large discs if the repair area is long.

3.4 Upon completion of the repair by the Repair Crew, the RWR will be returned to QC
with the date of the repair marked. This information will be processed by the NDT
Coordinator in order to re-radiograph the repair area and clear the weld for release.
3.5 Two repairs can be performed in a specific area of a weld joint. If after the second
repair the RT results are not acceptable, the weld joint will be cut out.

3.6 In cases where the type and extent of defect is such that repair is not practical, the weld
joint will be cut out. The decision for cut out will be taken by the QA/QC Department.

3.7 All repairs will be performed by qualified Welders who have a good performance
record.

3.8 If the thickness of run pipe is above 19 mm which is subjected to PWHT, in case of
delayed heat treatment, the repaired weld joint shall be immediately heat treated to 300
C and held at that temperature 20 minutes; and wrapped with Insulation Blanket
(Asbestos Cloth) for allowing slow cooling, as per GES-012-51 [6.2-Para (12)], and
PWHT will be carried out as per approved PWHT procedure record No. 001 dated
14.4. 1992.
 No. :
REQUEST FOR WELD REPAIR
Date :

NO. DRAWING NO. WELD NO. RT REPAIR INFORMATION REPAIR

NO. DATE