PCH STEEL ENGINEERING & CONSTRUCTION SDN. BHD.

Rev : 00 Document No. : PCH– QA – 004 Effective Date : June 22, 2019 Page 1 of 8

WELDING REPAIR PROCEDURE

00 June 22, 2019 IFR – Issued For Review Mr.Mohd Isnin Mr.Chuah
 PCH STEEL ENGINEERING & CONSTRUCTION SDN. BHD.

Rev : 00 Document No. : PCH– QA – 004 Effective Date : June 22, 2019 Page 2 of 8

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

TABLE OF CONTENTS

SECTION DESCRIPTION

SCOPE

1.0 OBJECTIVE / SCOPE

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2.0 REFERENCE

3.0 WELD REPAIR PROCEDURE FOR WELD DEFECTS

4.0 WELD REPAIR OF SURFACE DEFECTS ON BASE METAL

5.0 WELD REPAIR OF NOTCHES I GOUGES IN FLAME CUT EDGES

6.0 WELD BUILD-UP (BUTTERING) ON BASE METAL.

7.0 HARDNESS TEST REQUIREMENT AFTER REPAIR.

1.0 SCOPE
1.1 This procedure covers the methods/techniques of repair for weld defects and
surface defects or imperfection occurring in stainless steel and carbon steel base
metal as well as build-up (buttering) where required during the course of
fabrication work.
1.2 This procedure identifies the minimum requirements in respect of any welding
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repair/build up work to be performed, for compliance by production personal and

QC Inspectors.

2.0 REFERENCE
2.1 ASME IX 2007 EDITION 2009 ADDENDUM
2.2 APPROVED WPS/PQR.
2.3 ASME V 2007 EDITION 2009 ADDENDUM

2.4 AWS D1.l/l.1M 2008

2.5 HARDNESS TEST PROCEDURE (PCH-QA-006)

3.0 WELD REPAIR PROCEDURE FOR WELD DEFECTS

3.1 Identify the type, size, depth and location of defects detected by NDE, such as
radiographs, UT, MPI or DPT marked up on weld etc. Weld defects covered by
this procedure is limited to slag, porosity, lack of fusion, incomplete penetration
and minor cracks.
3.2 Gouge or grind the defective area to the required depth to remove the defects.

3.3 Upon completion of gouging to bare metal, the gouged surfaces shall be ground
to provide groove geometry that is acceptable for repair welding, as well as for
verification of complete removal of defect by in-house MT or PT as required.

3.4 Prior to depositing the repair weld, the excavated area and surrounding
weld and base metal shall be preheated to 50° C minimum, but not less
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than the original preheat specified in the WPS to which the weld was
originally welded to.

3.5 The repair welding shall be carried out by qualified welder(s) in

accordance with the applicable WPS approved and accepted by client,
preferably that was employed to deposit the original weld.
3.6 The completed repair upon acceptance by visual inspection shall be
Non- Destructively Examined by the same NDE method used detect
the original weld defect.
3.7 Any weld repairs shall be limited to 2 attempts, unless specially
approved by Client and accepted by the Third Party Inspector.
3.8 Method of removal weld defect by Gouging shall be prohibited for stainless

steel material. Only grinding with stainless steel disc will be use.

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.

4.0 WELDING REPAIR OF SURFACE DEFECTS ON BASE METAL

4.1 Any surface defect (with depth 10% material thickness or 3 mm

whichever is lower) such as undercuts, arc strikes (burns), gouge
marks, unacceptable mechanical damages etc on base metal shall be
removed by grinding and ascertain its removal by visual inspection. In
addition, arc strikes and gouge marks shall be subjected to MPI or
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DPT as appropriate after grinding. An NCR shall be raised for depth

exceeding the above limitations and the Client concunence obtained
prior to repair.
4.2 For removal of defects after grinding which causes reduction of base
metal thickness below minimum required, the ground area shall be built
up by welding using applicable approved WPS. The affected areas shall
be subjected to MPI or DFT as appropriate after welding and grinding
flush. Method of removal weld defect by Gouging shall be prohibited for
stainless steel material. Only grinding with stainless steel disc will be use.

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 materials.

5.0 WELDING REPAIR OF NOTCHES I GOUGES IN FLAME CUT EDGES

5.1 No direct repair welding shall be done in the flame cut
notches/gouges on the edges. Shallow notches/gouges up to 5 mm
depth may be ground to a smooth profile during normal production
welding.
5.2 Deep notches must be carefully ground to smooth sound metal. The
groove geometry should be prepared in such a manner that there is
good weld repair access and is free from conditions that will enhance
slag inclusion. Lack of fusion and other weld imperfection .
5.3 An approved WPS applicable to condition of repair shall be used.
5.4 Before commencing of repair, the base shall be preheated to the
mm1mum temperature specified in the WPS.
5.5 Weld repair shall cover the full cross section of the notch/gouge.
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5.6 Excess weld shall be ground smoothly and flush with adjacent
surface preserving the same configuration as the 01iginal edge.
5.7 Visual inspection and MPI or DPT as appropriate must be carried out after repair.

6.0 WELD BUILD-UP (BUTTERING) ON BASE METAL.

6.1 Weld build-up may be used for restoring thickness/length of base metal or
modifying the configuration of weld joint s on required parts to acceptable
dimensions to the extent permitted by Code or Client's Specification (ASME VIII
DIV. 1 2007 ED. 2009ADD. - Clause UW-42, ASME VIII DIV. 2 2007 ED.
2009ADD. - Clause 6.2.4.9, AWS D 1.1/1.1M : 2008 -Clause 5.22.4.3)

6.2 Weld build up shall preferably carried out prior to fit-up for welding, using applicable
approved WPS.
6.3 Preheat the areas for weld build up including surrounding areas to minimum
temperature required by the WPS considering the thickness of the material,
whichever is greater.
6.4 Build-up welding shall be done using low hydrogen electrodes according to
qualified procedures with string bead technique, and preferably in flat or
horizontal position.
6.5 Where necessary, datum point shall be punched on base metal for measuring the
build-up weld thickness. The weld built-up area shall be subjected to DPT or MPI
as appropriated detection prior to fit-up for welding.
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7.0 HARDNESS TEST REQUIREMENT AFTER REPAIR.

7.1 Hardness test shall be conducted after each repair is done.

7.2 Detail method, frequency of testing and acceptable hardness value shall refer to
latest revision of PCH Hardness Test Procedure PCH-QA-006