REPAIR PROCEDURE FOR Doc No: STS/QAC/SOP/07

Rev No: 00
CARBON STEEL Date Rev: 17 Dec 2008
Page No: 1 of 6

REVISION HISTORY

Rev Originator Description Of Amendments Date

00 Farid New Document 17.12.2008

Designation Name Signature

Originator Mechanical Eng Mohd Farid Abu Bakar

Reviewed

Approved

Controlled document: No part of this document may be printed or reproduced for external purposes
without the written permission of the management appointee of Science-Tech Solutions Sdn Bhd.

SCIENCE-TECH SOLUTIONS SDN BHD

1. SCOPE

This procedure provided for general requirement for repair of defect such as crack, pinhole etc. and
detected by magnetic particle testing (MPT) and dye penetrant (DPT).

This procedure is only relevant to Carbon Steel (P-No. 1 material)

2. REFERENCE CODES & STANDARDS

2.1. ASME VIII Div. 1

2.1.1. UW-42, “ Surface weld metal build-up”
2.1.2. UW-38, “Repair at weld defect”
2.1.3. Appendix 6,”Method for Magnetic Particle Test”
2.1.4. Appendix 8, “Method for Liquid Penetrant Test”

2.2. ASME Section IX

2.3. ASME V
2.3.1. Article 6. “Liquid Penetrant Test”
2.3.2. Article 7. “Magnetic Particle Test”

3. SPECIFICATION

3.1. Welding Procedure Specification (WPS) available as list below:

WPS No. P-No. Range Welding Process

STS/WPS/(M)/001 P1 to P1 GTAW

STS/WPS/(M)/002 P1 to P1 GTAW/SMAW

4. PROCEDURES

4.1. SEQUENCE OF WORKS

4.1.1. 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.

Note: The gas test shall be conducted to ensure that there is no gas leak. Work leader or
supervisor needs to liaise with PPMSB Operation for gas test prior to commissioning any
hot work.

4.1.2. Sequence of works for any contingency repair is as follows:-

4.1.2.1. The equipment to be inspected should be cleaned to remove any dirt, grease, oil
etc.
4.1.2.2. All weld seams either circumferential or longitude and defective area should be
power brushed or solvent to remove any rust, dirt, grease, oil etc.
4.1.2.3. CLIENT representative shall identify any abnormalities will conduct a visual
inspection and mark the area to be repaired.
4.1.2.4. The removal of such abnormalities shall be done by grinding by appointed
operator to the identified areas until all detected defect removed.
4.1.2.5. 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 )
4.1.2.6. All sharp edges shall be carefully ground to remove sharp edges. Extra care
should be given not to damage the nearby area.
4.1.2.7. Contractor supervisor must supervise all grinding work activities.
4.1.2.8. CLIENT representative shall be notified to conduct visual inspections in order to
identify the defect is satisfactory removed up to standard requirement.
4.1.2.9. A MPT/DPT shall then be carried out to confirm that there are no other defects
present on the equipment after the repair is completed.
4.1.2.10. Should depth exceed 2 mm, the following step shall be used. The defect surface
shall be lightly grounded to prepare a surface preparation prior to build up (or
wire brushing for areas non-accessed by power tool).
4.1.2.11. Welding repair process shall be strictly complying accordingly with the
following documents (refer attachments) which are relevant and approved by an
authorized party before work started.
4.1.2.12. A pre-heat minimum of 250 ̊C is required prior welding work. After welding
work, immediately wrap blanket at welding location and let it cool in covering
condition.
4.1.2.13. The welded surface shall be dressed smoothly by grinding. CLIENT
representative shall witness and review MPT/DPT activity to confirm that there
are no other defects present at equipment repaired.
4.1.2.14. The repaired area then shall be inspected as per Section 4 to ensure that the
defect has been completely removed and no defect surface is present and within
tolerant.
4.1.2.15. If there is any defect surface on unsatisfactory result observed, the job must be
repeated from Clause 4.2.10 to Clause 4.2.15 again.
4.1.2.16. After all repair activity is satisfied by all parties, the exchanger will be hydro
tested and witnessed by CLIENT and DOSH representative.
4.1.2.17. After repair activity has finished, PWHT will be conducted at repaired area.
CLIENT and DOSH representative will witness the PWHT activity (if
applicable).
4.1.2.18. When the repair is satisfied and accepted, the equipment shall be housekeep to
avoid any foreign material left behind which can cause a hazard to this
equipment.
5. ACCEPTANCE CRITERIA

5.1. Acceptance/ rejection criteria for all testing shall be as per below:

5.1.1. Visual inspection and evaluation shall be as UW-42 or UW-38 (ASME Section VIII, Div.
5.1.2. Dye Penetration Testing or Magnetic Particle Testing as per Appendix 6 or Appendix 8.
(ASME Section VIII, Div.)
6. WORKFLOW
7. APPENDIX

7.1. WPS/PQR
7.2. WQT