TITTLE:

WELD REPAIR PROCEDURE

LINE NO:400-WT-4820-70524-1S105DC-N

CLIENT:

UTILITIES & FACILITIES

(UF)
 Aug 01,
00 IFR – Issued For Review Mohd As shahiddin
2019

CHECKED
REV DATE STATUS – REVISION MEMO PREPARED BY APPROVED BY
BY

TABLE OF CONTENT

1.0 PURPOSE 1
2.0 SCOPE 1

4.0 APPLICABLE CODES & STANDARD 1

5.0 CONSUMABLE 1

6.0 WELDING PROCEDURE SPECFICATION (WPS) 1

7.0 MATERIAL 1

8.0 PREPARATION WORK 1

9.0 SAFETY 2

10.0 WORKFLOW 2

8.0 ACCEPTANCE CRITERIA 3

8.0 ATTACHMENT 3

a. Weld Map

b. WPS

c. Welder Qualification Record

d. Welding Inspection Control Sheet (WICS)

1. Purpose
This procedure serves as a guide line in carrying out piping fabrication to ensure systematic approach of
work and the requirement are followed

2. Scope
This procedure covers the processes associated for the piping fabrication such as mark ,cutting,fit
up,weld up,testing & painting etc

3. Applicable Code Reference

ASME B31.3 - Process Piping
PTS 15.12.01 - Welding for Chemical, Oil, and Gas Industries
ASME Section IX - Qualification Standard for Welding, Brazing, and Fusing Procedures
ASME Code Sec V - Nondestructive Examination

4. Consumable
Brand :TG-S316
Size :2.4
SFA No :A5.9
AWS Class :ER316

5. Welding Procedure Specification (WPS)

WPS No :STS/WPS/(M)/010
PQR No :STS/PQR/010
Process :GTAW/SMAW

6. Material
 Stainless Steel 16”Sch 10S (OD 406.4mm x 4.78wt)
Stainless Steel (P-No. 8 material)

7. Execution of work

Submit Welding Inspection Control Sheet (WICS) together with WPS,WQT & Specific Repair
Procedure to PRPC UF for review and approval.Welding work shall be performed as per approved
WPS by qualified welder and shall be monitored by supervisor (before, during and after)

8. Piping Material Receiving and Storage

Prior to material arrival at site, the inspector shall carry out the following work.

Obtain pipe material Purchase Order (P.O.), packing list and shop inspection mill certificates.

The inspector shall identify the quantity, type and size of the piping as a reference to inspect the storage

area to be provided and the storage method / requirement.

Prepare the receiving inspection record forms. Project specific forms are recommended.

Inspect the pipe material for damages that may occur during shipping / handling.

Damage report shall be prepared and submitted to Contractor/Owner. The damage report shall contain

damage type and identification of rejected and accepted material.

The damage report of rejected material shall quote the appropriate specification as reason for rejection.

Identify the material of pipe shall conform to the purchase order.

Check sizes, type of pipe fittings, flanges etc. to conform to P.O.

Verify the mill certificates :

Ladle analysis (chemical composition) shall conform to tabulated composition in the standards &

specification.
 Tensile strength and ultimate strength value shall conform to strengths as tabulated in the standards &

specification.Other specific certificates (valves, flame arrestors etc.).

9. Piping Material Storage Inspection.

Inspection to ensure the piping material is placed in the storage area properly:

Pipe or fitting stainless steel shall be separated with carbon steel / galvanized material

Protected against weather or corrosion, refer to project specific requirement.

Each piping component or group shall have material identification tag.

Surface of plunges shall be protected with wood or rubber / plastic.

Rejected material shall be stored separately to avoid misuse and shall have special identification (e.g.

rejected, do not use etc.).

10. Fabrication Area

Fabrication of the different materials, carbon steel and stainless steel materials will be carried out in
separate designated areas. The stainless steel materials will be fabricated at the shop or field. Work areas
for stainless steel materials shall be separated from carbon steel work areas. Stainless steel materials will
be stored in separate areas on the timber lined floor of the stock area and will be moved by the use of
web slings or by hand into clean timber / rubber lined trestles / work benches. There shall be no direct
contact between carbon steel and stainless steel material under any circumstances. Tools for use on
stainless steel, carbon steel materials will be kept in separate tool boxes under the control of the material
controller and foreman. All tools such as wire brushes, cutting tools for facing machines will be
identified by color codes for carbon steel, and stainless steel material

11. FABRICATION SEQUENCE

The spool fabrication will be implemented with the sequence of marking, cutting, fit-up, welding, and
painting,Marking
 All materials shall be marked for identification and trace ability

All materials shall be marked for identification and trace ability purposes as follows :

Installation area,sheet number,Spool number

The cut pipe spools shall be marked with their respective spool numbers, in accordance with the marked
up fabrication drawing.

The method used for marking shall not result in contamination of the Material, significant strain
hardening, or sharp discontinuities.

Marking for cutting shall include all dimensions (diameter, Wall thickness, length) and the joint detail of
drawings and be done exactly taking into consideration allowance for welding shrinkage and cutting loss.

In case the original identification markings are unavoidably cut out or The material is divided into two
or more parts, the marking shall be Accurately transferred for each pieces prior to cutting to a location
Where the marking will be visible on the completed spool.

12. Cutting and Edge preparation

Carbon steel shall be cut by method of flame cutters or.

Stainless steel shall be cut by a plasma cutting machine If plasma arc cutting is done the following
procedure is employed.

Large sized pipes (above 28" NPS) and holes of branch connections shall be cut by a plasma cutting
machine.

When cutting starts, if access permits, a receiving basket for spatters shall be inserted in the inner
cutting area of the pipe to avoid adherence of spatters to internal wall of pipe.

If the cutting area is inaccessible, a spatter compound is applied to the inside cutting area by brush, roller
or swab. The application of the compound is applied completely around circumference, a minimum of
200 ㎜ each side of the cutting area.After cut, the anti-spatter compound shall be removed by clothes or
other methods.
 All materials cut by a flame or arc shall have the edge ground back to clear the affected zone. The
grinding wheel is marked by an impregnated red dye in the make-up of the disc which denotes chloride
free material when used for stainless steel. Wire brushes with stainless steel bristles will be used,
dedicated to stainless steel and high alloy materials. Files for use on stainless steels and non ferrous
alloys shall be NEW and dedicated to a particular alloy only.

All edges shall be accurately maintained as per design requirement with a smooth even surface with all
slag removed.

Beveling will be performed with a grinder. Separate machines will be used for carbon steel and stainless
steel. Preparation will be in accordance with the approved

The preparation of edge for welding shall be done by machining or grinding.

Edge preparation shall be performed in accordance with the approved WPS.

The surfaces of the edge preparation shall be free from tears, grease, oil slag, scale or internal burrs.

Stainless steel shall be beveled by a grinding. Separate machines will be used for carbon steel and
stainless steel.

13. Welding

All welds shall be performed in accordance with the approved WPS and Welding material control
procedure which shall be displayed on a notice board close to the work.

Any cracks, blowholes, cold laps, unusual irregularities, slag, flux, or other impurities that appear on the
surface of any welding bead shall be removed by grinding or chipping before depositing the next
successive bead. In the case of submerged arc welding of carbon steel the removal method used may be
air arc gouging, which shall be cleaned out by grinding to shiny metal.

The requirement of the finished weld reinforcement for all materials should comply with ASME B 31.3
specification for piping.
 If arc strike occurs, this shall be removed by grinding with Company's prior approval. The ground area
shall be inspected by MT (carbon steel) or PT (stainless steels).The remaining wall thickness shall not
be less than the stipulated minimum, as stated in specification or ASME B 31.3 If pipe is ground
severely to repair, the damaged part of the pipe shall be removed.

Internal purge of argon shall be used for the GTAW process root pass on stainless steels as specified by
WPS

2.1. Piping Spool Shop Fabrication.

a) Construction Drawings

- The inspector shall check the isometric drawings had been checked and approved for
construction.

- The isometric drawings to be used for fabrication were marked at shop for spool number, welds
number and WPS number.

- Spool drawings were checked by Piping Construction Group (by project engineer) for correct
dimension, identification of pipe cutting length, fittings and flanges.

Selection of the correct fittings and flange (shall be in accordance with isometric drawings) will
be by the Construction Group but the inspector shall inspect and notify them if any discrepancy
occur.

b. Check Welders certifications

 - The welder’s certification of the welders shall be checked that they have certificate copy handy.

Identify the certificates corresponds to which WPS. This avoids misuse of welder.

- Ensure that the welders use welder badge identifying their qualification.

c. Welding Facility.

- Inspect to ensure the welding machines have proper amperage capacity (WPS requirement),
stable voltage etc.

- Inspect that welding holder in good order.

- Inspect space for welding to ensure welder free movement as required during welding. This will
avoid weld defects.

- Inspect whether welding tents is needed to avoid winds during welding. Strong wind may cause
blowhole or porosity on welds.

- Inspect the welding electrode heater for storage and heating of welding electrode for immediate
use. Heating temperature as per manufacturer recommendation shall be checked.

- Inspect size of grinder and grinding wheel to match the need for weld joints

d. Welding of Pipe Spools

- Inspect to ensure fit – ups work utilizes proper method as usually in construction practice (use
of angle, level, clamp etc.).

- Inspect to ensue that fit – up tack welding is done by qualified welder. Check the welding
electrodes used conform to WPS.

- Inspect randomly that weld bevel angle and gap are correct in accordance with WPS.

- Inspect to ensure that each welded spool is marked to identify the isometric drawing & mark
number, each weld with welder number, welding date and radiography number / date shot.

- Refer to project specification procedure for further requirements of inspection.

a. Prior to start work, all required permit shall be applied and all piping/line that connect to the equipment
shall be suitably blank-off, isolated by spades, reverse spectacle blind,ventilation and etc

b. The equipment to be inspected should be cleaned to remove any dirt, grease, oil etc.Grinding Disc / wire
brush must be a suitable type to the material of equipment repair.(segregation on storage of stainless
steel wire brush and disc
c. CLIENT representative shall be notified to conduct visual inspections in order to identify the defect is
satisfactory removed up to standard requirement.

d. 1st Step - Make a bevel in the leaking area using by power tool

e. 2nd Step - Cleanness weld area to remove dust or etc

 f. 3rd Step - Weld up to completed and apply the DPI on the weld surface to ensure the joint free from
defect.

g. After welding completed apply the DPI for The welded surface shall be dressed smoothly by grinding

h. CLIENT representative shall witness and review MPT/DPT activity to confirm that there are no other
defects present at equipment repaired.

Note: Only stainless steel power or hand brushes and non-contaminated iron free Grinding disc or chipping
tools shall be used on repair of stainless steel.

14. Safety
All condition must comply with Permit to Work (PTW).
All conditions stated in the Job Safety Analysis (JSA) must be followed.
All personnel working on the job site shall be informed of the safety awareness by attending the safety
induction conducted by client representative prior to commencing work.
Full PPE and fire watcher is required to ensure personnel safety whilst working at site.

15. Work flow

16. Acceptance Criteria
Visual inspection and evaluation shall be as UW-42 or UW-38 (ASME Section VIII, Div.
Dye Penetration Testing Appendix 8. (ASME Section VIII, Div.)

17. Attachment
Welding Procedure Specification
Sketch
Welder Qualification Record
Welding Inspection Control Sheet (WICS)