STSSB/PCE/TA14/PR003

PIPING REPAIR WELD Rev :1

PROCEDURE Date
Page
: 22/03/14
: 1 of 4

PIPING REPAIR WELD

PROCEDURE

PROCEDURE DEFECT RECTIFICATION WORKS

FOR PCESB TA 2014

1 23/3/14 ZULFADLI SHAHARUDDIN

0 25/2/14 JEFF ZULFADLI
PREPARED APPROVED
REV DATE CHECKED BY REVIEWED
BY BY
BY
 STSSB/PCE/TA14/PR003
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PIPING REPAIR WELD Date : 22/03/14
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TABLE OF CONTENTS

1.0 SCOPE

2.0 APPLICATION

3.0 REFERENCES

4.0 PROCESS PIPING WELD REPAIR WORK

INSTRUCTION

CATEGORIZATION OF WELD REPAIR

4.1 MAJOR REPAIRS

4.2 MINOR REPAIRS

5.0 ATTACHMENT
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1.0 SCOPE
1.1 This procedure details the steps necessary to effect high quality weld repairs in
accordance with Client’s requirements.

2.0 APPLICATION
2.1 This procedure applies to all Company operations and Company’s Subcontractors’
operations during work performed on STS project.
2.2 When making weld repairs, Supervisors shall ensure that workers follow the
instructions listed in this procedure.

3.0 REFERENCES
3.1 ASME section IX
3.2 ASME B31.3
3.3 ASME II Part C
3.4 ASME VIII
3.5 PTS 31.38.01.31

4.0 PROCESS PIPING WELD REPAIR WORK INSTRUCTION

Categories of Weld Repair
4.1 MAJOR repairs - Repairs requiring removal and replacement of weld metal
4.2 MINOR repairs - Superficial repairs requiring grinding only
Cut off weld - 2inch and below require cut off if RT rejected

4.1 MAJOR REPAIRS

4.1.1 A maximum of two attempts may be made to repair a weld in any given area.
4.1.2 Before excavating defect, confirm with RT tracing defect or UT defect marking
where is the exact defect location.
4.1.3 Before excavating defect area, preheat to a minimum of 66C. The width of the
preheated area shall be a minimum of 3 times the base metal thickness or 51mm
whichever is greater. Length of the preheated area shall be 3 times the length of
the defect or 152mm, whichever is greater.
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4.1.4 Excavate the defect by grinding. Tolerance of excavation six is allowed to

minimum width of excavation shall be 13mm and minimum length shall be
76mm. Where size of weld makes it impossible to achieve these dimensions, the
following minimum excavation size shall be acceptable:
* Width – equal to the cross sectional thickness of the original weld
* Length - 10 times the length of the weld defect.
4.1.5 After excavation and cleaning, check with MPI or Dye Pen inspection to ensure
defect has been removed.
4.1.6 Before depositing weld metal, preheat to a minimum of 94C. The minimum
width of the preheat area shall be 6 times the base metal thickness or 76mm,
whichever is greater and the minimum length shall be 3 times the length of the
excavation.
4.1.7 Fill the excavation using the consumables and welding parameters as stated on
piping WPS used for the original weld and blend into original weld.
4.1.8 After welding, wrap the repaired area in a fire blanket to slow the cooling rate.
4.1.9 All repairs must be performed prior to PWHT (when PWHT is required).
4.1.10 Perform Visual Inspection and NDT utilizing the same NDT method as originally
detected the defect.
Ensure that the Weld Repair Record is filled out with the following information:
a) Type, location and depth of defect with sketches
b) Material grade and thickness
c) Welding Procedure used to make repair
d) Preheat and PWHT data (if required)
e) NDT methods used with Report No. (before and after repair)
f) Hardness values (if required by Owner)

4.2 MINOR REPAIRS

4.2.1 Grind or file superficial defects (cap and toe) and blend to eliminate sharp edges.
4.2.2 Visually check to ensure that minimum parent material thickness is maintained. If
parent material thickness cannot be determined visually, check with UT.
4.2.3 If parent material thickness requires building up it shall be treated as a MAJOR
repair and the steps listed in Para 4.1 shall be followed.
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5.0 ATTACHMENTS:

Date Date Date Date

Type
Location
Depth of defect
Material defect
Thickness
Preheat
(PWHT)
NDT
Hardness