Company Document No.

WELDING OVERLAY PROCEDURE FOR IK QC-09-038

VARIOUS FLANGE (RF AND RTJ)
Revision: 0.3 Status: IFA

Doc. Type: SOP Sys./S.Syst: NN Discipline: PVV Revision Date: 11-August-2020

Page: 1 of 8

ISO 9001 : 2015

PT. DUTA KATUP MAS
PT. DUTA KATUP MAS
This document has been generated by an Electronic Document Management System. When it is printed, it shall be considered as "For information only copy".
The controlled copy is the screen version, and thus, it is the holder's responsibility to make sure that he/she holds the latest valid version.

WELDING OVERLAY PROCEDURE FOR

VARIOUS FLANGE (RF AND RTJ)

0.3 11-August-2020 IFA Issued for Approval ATD HRY

0.2 24-July-2020 IFA Issued for Approval ATD HRY
0.1 16-July-2020 IFC Issued for Comment ATD HRY
DKM ARUNG PHM PHM
Issued Checked Approved Approved
Rev. Date Status Revision Memo
by by by by

This document is the property of DKM and shall not be disclosed to third parties or reproduced without permission of the
COMPANY
 Company Document No.

WELDING OVERLAY PROCEDURE FOR IK QC-09-038

VARIOUS FLANGE (RF AND RTJ)
Revision: 0.3 Status: IFA

Doc. Type: SOP Sys./S.Syst: NN Discipline: PVV Revision Date: 11-August-2020

Page: 2 of 8

Revision Table
ATTACHMENTS
REVISIONS
PAGE REMARKS REVISIONS REMARKS
ATT PAGES
0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5
1 X
2 X
3 X
4 X
5 X
6 X X X
7 X X
8 X X

REVISIONS
EXHI. PAGES REMARKS
0.1 0.2 0.3 0.4 0.5

This document is the property of DKM and shall not be disclosed to third parties or reproduced without permission of the
COMPANY
 Company Document No.

WELDING OVERLAY PROCEDURE FOR IK QC-09-038

VARIOUS FLANGE (RF AND RTJ)
Revision: 0.3 Status: IFA

Doc. Type: SOP Sys./S.Syst: NN Discipline: PVV Revision Date: 11-August-2020

Page: 3 of 8

REVISION DETAIL TABULATION

DATE PAGE REVISION REVISION DETAILS

24-July-2020 6 0.2
Additional paragraph of parts of the welding
overlaid flange should be PMI Test
11-August- All tools & equipments should be have valid
6 0.3
2020 calibration certificate
11-August- Fabration can be started if design drawing had
6 0.3
2020 approved
11-August- Finished face after machining should be checked
6 0.3
2020 by visually and DPT
11-August- Dimensional check before welding overlayed
7 0.3
2020 flange should be done
11-August- Check dimensional and surface roughness after
8 0.3
2020 re-machining

This document is the property of DKM and shall not be disclosed to third parties or reproduced without permission of the
COMPANY
 Company Document No.

WELDING OVERLAY PROCEDURE FOR IK QC-09-038

VARIOUS FLANGE (RF AND RTJ)
Revision: 0.3 Status: IFA

Doc. Type: SOP Sys./S.Syst: NN Discipline: PVV Revision Date: 11-August-2020

Page: 4 of 8

TABLE OF CONTENTS

1. PURPOSE ..................................................................................................................... 5
2. CODE & STANDARD ................................................................................................ 5
3. TOOLS & EQUIPMENT ............................................................................................ 5
4. WELDING PROCEDURE ......................................................................................... 6
4.1. GENERAL ............................................................................................ 6
4.2. MACHINING OLD RF OR RTJ FLANGE SURFACE .................................. 6
4.3. WELD OVERLAY APPLICATION ................................................................... 7
4.4. INSPECTION ........................................................................................................ 8
5. ATTACHMENT ........................................................................................................... 8

This document is the property of DKM and shall not be disclosed to third parties or reproduced without permission of the
COMPANY
 Company Document No.

WELDING OVERLAY PROCEDURE FOR IK QC-09-038

VARIOUS FLANGE (RF AND RTJ)
Revision: 0.3 Status: IFA

Doc. Type: SOP Sys./S.Syst: NN Discipline: PVV Revision Date: 11-August-2020

Page: 5 of 8

1. PURPOSE
The Purpose of this procedure is to provide working procedure for various
flange (RF and RTJ), detail various flange are SW Flange 1,5” #300 RF Sch. XXS,
WN Flange 2” #300 RF Sch. XXS, WN Flange 8” #900 RTJ Sch. 120, WN Flange
18” #900 RTJ Sch. 100. The Flange weld overlay work and make sure that the
weld overlay accordance with the standard and specification.
This work is performed by qualified Welding Procedure Specification and welder of
PT. Duta Katup Mas.

2. CODE AND STANDARD

 MHK COMP SPE EP PVV 0611 Rev. 01
 MHK COMP SPE EP PVV 0145 Rev. 01
 ASME B16.34, Valve - Flange, Threaded and Welding end
 ASME B16.5, Pipe Flanges and Flanged Fittings
 ASME Section IX, Latest Edition
 ASME B & PV Code Sect. I, V, VIII Div. 1, Latest Edition & Addenda Accepted
By Code Section and SNT-TC-1A.

3. TOOLS AND EQUIPMENT

 SMAW Welding Machine complete unit
 Grinder Machine
 Stainless Steel Grinding Disk
 Stainless Steel Brush
 Hand Brush
 Lathe Machine Unit
 Tang Ampere
 Marker
 Hand Cutting

This document is the property of DKM and shall not be disclosed to third parties or reproduced without permission of the
COMPANY
 Company Document No.

WELDING OVERLAY PROCEDURE FOR IK QC-09-038

VARIOUS FLANGE (RF AND RTJ)
Revision: 0.3 Status: IFA

Doc. Type: SOP Sys./S.Syst: NN Discipline: PVV Revision Date: 11-August-2020

Page: 6 of 8

 Infrared Temp. Thermometer

 Digital Surface Roughness Tester
 Penetrant equipment
 PMI Tester.

4. WELDING PROCEDURE
4.1. GENERAL
4.1.1. All welding shall be performed based on approved and qualified
welding procedure as per ASME Section IX, 2013 edition. Welding
process and other variable shall be refer to the approved WPS no. :
008/WPS/DKM/2015 & and PQR no. : 008/PQR/DKM/2015.
4.1.2. The essential variable of welders certificate and welding operators are
based on ASME Section IX, QW-350 and QW-360.
4.1.3. Welding variables shall be based on ASME Section IX, QW-250 for
applicable process.
4.1.4. NDT examination refer approved NDT Procedure.
4.1.5. Parts of the welding overlaid flange should be PMI Test.
4.1.6. All tools & equipments such as tang ampere, infrared temp. thermometer,
Digital surface roughness tester and PMI tester should be have valid
calibration certificate.
4.1.7. Fabration can be started if design drawing had approved.

4.2. MACHINING OLD RF OR RTJ FLANGE SURFACE

4.2.1. Cutting or machining old RF or RTJ Flange (refer to drawing document)
surface as per attachment.
4.2.2. Surface Preparation shall be made by machining, grinding and the
surfaces shall be smooth.
4.2.3. Finished face after machining should be checked by visually and DPT to

This document is the property of DKM and shall not be disclosed to third parties or reproduced without permission of the
COMPANY
 Company Document No.

WELDING OVERLAY PROCEDURE FOR IK QC-09-038

VARIOUS FLANGE (RF AND RTJ)
Revision: 0.3 Status: IFA

Doc. Type: SOP Sys./S.Syst: NN Discipline: PVV Revision Date: 11-August-2020

Page: 7 of 8

check there is no crack.

4.2.4. Dimensional check before welding overlayed flange should be done as
per design drawing had approved.

4.3. WELD OVERLAY APPLICATION

4.3.1. Preparation for welding, types and sizes of electrodes, current
amperages and voltages used, preheating requirements etc. shall be
refer to WPS No. 008/WPS/DKM/2015.
4.3.2. Welder shall be have qualified welder certificate by MIGAS.
4.3.3. Weld surfaces shall be free of cracks, porosity, slag inclusions and
other defects indicative of poor workmanship.
4.3.4. The heat input, in conjunction with the minimum preheat and
maximum interpass temperatures, shall be restricted to the maximum
values shown in the relevant WPS and PQR. Preheat shall be
maintain at 100°C until first layer completed.
4.3.5. Weld reinforcement and finish shall be as required by the
applicable Code.
4.3.6. There shall be no less than two layers of corrosion ressistant weld
(Ref : MHK COMP SPE EP PVV 0611 Rev. 01, Appendix 4) and shall
be no less than 3 mm thickness of corrosion-resistant weld metal
after machining as per approved WPS.
4.3.7. The first layer of deposited weld metal shall be E 309-16 stainless steel.
4.3.8. After the first layer has been deposited, wait for cooling down. Cooled
down up to room temperature.
4.3.9. For subsequence or final layer of deposit shall be E 316L-16 filler metal
as per WPS No. 008/WPS/DKM/2015.
4.3.10. After overlay welding new flange shall be remachining.
4.3.11. Surface roughness measurement using digital roughness meter refer
to acceptance criteria ( 3.2 µm to 6.3 µm ) Ra for RF flange as per

This document is the property of DKM and shall not be disclosed to third parties or reproduced without permission of the
COMPANY
 Company Document No.

WELDING OVERLAY PROCEDURE FOR IK QC-09-038

VARIOUS FLANGE (RF AND RTJ)
Revision: 0.3 Status: IFA

Doc. Type: SOP Sys./S.Syst: NN Discipline: PVV Revision Date: 11-August-2020

Page: 8 of 8

MHK COMP SPE EP PVV 0145 Rev. 01.

4.3.12. Perform Liquid penetrant testing as per IK-09-011 to make sure no
defect or crack on RF or RTJ.
4.3.13. Check dimensional after re-machining as per design drawing had
approved and surface roughness check as per MHK COMP SPE EP
PVV 0145 Rev. 01.

4.4. INSPECTION
4.4.1. Visual Inspection
Checking the weld defects while the welding process as blowhole,
undercut, overlap, porosity, crack, weld spatter, etc.
4.4.2. Perform Dye Penetrant Testing ( 200 ppm maximum chloride contenct
type) for new RF or RTJ after machining as per IK-09-011,
DKM procedure.
4.4.3. Check Dimensional of RF or RTJ Flange as per shall be as per
requirement MHK COMP SPE EP PVV 0145 Rev. 01 for roughness.
4.4.5. PMI Test should be done refer to MHK COMP SPE EP PVV 0145
Rev. 01.

5. ATTACHMENT
a. DRAWING OF VARIOUS FLANGE
b. MILL CERTIFICATE OF VARIOUS FLANGE
c. WPS & PQR WELDING OVERLAY NO. 008/WPS/DKM/2015
d. WELDER CERTIFICATE
e. MT & PT CERIFICATE

This document is the property of DKM and shall not be disclosed to third parties or reproduced without permission of the
COMPANY