WELD REPAIR PROCEDURE

2 25.01.2018

1 25.04.2017

0 05.03.2014
Welding QCE
AI
Engineer
Rev Date Prepared By Reviewed / APPROVED By Accepted By
. Approved
 REVISION RECORD SHEET

Reviewed &
Prepared by
No. Date Description of revision approved by Remarks
QCI
QCE

0. 05/03/2014 First Issue

Revised Para 3.0 to Indicate

Revised Para 3.0 to revise

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 PROCEDURE

4.1 Identification of Defects

1.0 PURPOSE
1.1 The purpose of this procedure is to provide the minimum requirements while carrying out
repairs to the welded joints of Pressure vessels, and Pressure retaining parts fabrication as
per applicable Codes and Client specifications.
2.0 SCOPE
2.1 This procedure applies to repairs to the weld joints identified during manufacturing of
pressure vessels, pressure retaining parts and other components during the following
inspection stages.
A) In process inspection of welding
B) Visual inspection of completed welds
C) Dimensional/Distortion correction
C) Non destructive examination of welds
D) Hydrostatic / Pneumatic testing
2.2 This procedure is not applicable for repairs to the pressure part materials (excluding areas
of temporary attachments on pressure parts required for the fabrication purpose and to
maintain the required dimensions). Such repairs to the materials are not permitted until
prior concurrence of the Authorized Inspector has been obtained.
3.0 REFERENCES
3.1 ASME Sec VIII Div.1 Edition 2017 : Boiler & Pressure Vessel Code-Rules
for construction of Pressure Vessels

3.2 ASME Sec V Edition 2017 : Boiler & Pressure Vessel Code –
Non-Destructive Examination

3.3 ASME Sec. IX Edition 2017 : Qualification standard for welding, Fusing,
Brazing Procedures; Welders; Brazers; And
Welding, Brazing, and Fusing Operators
3.4 QCM : ASME Quality Control Manual
(LatestRevision)

4.0 PROCEDURE

4.1 Identification of Defects

4.1.1 QC Inspector shall identify the type, size and location of the defects during in process
inspection and / or NDE evaluation, those areas evaluated as discontinuities shall be marked
on the part to be repaired.
4.1.2 Discontinuities that are identified through radiography; a tracing shall be taken from the
radiograph to show the size and location of defect.
4.1.3 Production Engineer shall be responsible for supervising the repair work as per this
procedure.
4.2 Qualification of Welders and Welding Operators

4.2.1 Welders and Welding operators qualified as per ASME Code Sec IX shall be engaged to
perform repair welding.
4.2.2 Where practicable, same welders & welding operators shall be engaged for repair
welding who made initial weld. In any case, record of the welder used for repair shall be
kept as per Chapter 10 of QCM
4.3 Welding Procedure Qualification

4.3.1 WPS qualified and approved in accordance with Chapter 10 of QCM shall be used for
repairs. WPS used for initial welding may be used for carrying out repairs. When
required, alternative WPS shall be indicated on the Welding & NDE Plan. Additional
requirements if any as per Code or client shall be indicated in Welding & NDE Plan
4.4 Pre heat and Interpass Temperatures

4.4.1 Preheat and interpass temperature shall be in accordance with approved WPS.
4.4.2 Minimum preheat and interpass temperature shall be maintained throughout the duration
of repair welding.
4.4.3 Minimum preheat temperature shall also be applicable for arc gouging.
4.5 Execution of Repair Welding

4.5.1 Based on the acceptance of this procedure by AI & Client the weld repairs can be
progressed without taking their prior concurrence provided the repairs meet all of the
following conditions.
 Repairs are limited to P1, P3, P4 or P8 materials
 Defects are not identified as planer in nature (Crack, Lack of Fusion or Lack of
penetration)
 Defects are either rounded type (porosity) or linear volumetric type (slag inclusion)
not exceeding 10% of the length examined.
4.5.2 The above conditions are not applicable for repairs in tack welds or temporary welds.
4.5.3 Defects shall be removed by grinding and/or arc gouging process. Arc gouging when
used shall be followed by grinding to remove heat affected and uneven areas
4.5.4 The ground areas shall be visually PT or MT examined to ensure complete removal of the
defects.
4.5.5 The width and the profile of the groove shall be such as to allow sufficient access for the
repair welding.
4.5.6 The length of the repair shall not be less that 25 mm. Depth shall be such as to allow a
minimum of two passes.
4.5.7 When it is not practical to carry out local repairs (for example in small diameter pipes),
complete weld shall be cut and the joint re-welded. Weld edges shall be examined by PT
or MT before depositing new welds.
4.6 Method Statement for Critical Repairs

4.6.1 When required, specific method statement or Inspection and Test Plan shall be prepared
for critical repairs affecting the integrity of vessel or component.
4.7 Visual Examination

4.7.1 All repair welds shall be visually examined by QC Inspector prior to NDE and recorded
in the Weld Inspection Report (QCM /F/22)
4.8 NDE Examination

4.8.1 After completion of repair welding, repaired area shall be re-examined by the same
methods and to the same acceptance standard as required for the original weld. When
required, additional examination or alternative method of NDE can be asked by QCE or
the AI
4.9 Records

4.9.1 NDE & Welding Inspection Reports for each weld joint repairs shall be maintained by
QCI. All repair records shall be made available to the AI for review and acceptance.