Duqm Refinery Project EPC

Package One

Duqm Refinery Project EPC Package One

PROJECTNO:10121 UNIT:120

PURCHASE ORDER NUMBER (RFP):1012125370 EQUIPMENT:120F-001/120F-002/-120F-003

REVIEW RESPONSE BY PURCHASER:

Purchaser review and comments do not indicate either responsibility or liability for accuracy and completeness of
this document or alter any contractual terms and conditions:

REJECTED. NOT ACCEPTED REVIEWED WITH COMMENTS REVIEWED WITHOUT COMMENTS

COMMENTS AS NOTED REVIEWED AS BUILT FOR INFORMATION

VOID

DATE:

SUBCONTRACTOR IDENTIFICATION: TECNICAS REUNIDAS LLC

DOCUMENT TITLE: WELD REPAIR PROCEDURE (ELCO)

SUBCONTRACTOR DOCUMENT No.: REV: 0 CODE: PRC-0048

DRP001-PUC-TRL-P88-120-3025
CONTRACTOR DOCUMENT No.: REV: 1 DOCUMENT CLASS:
DRP001-PUC-V-1012125370-0024 3
 WELD REPAIR PROCEDURE

WELD REPAIR PROCEDURE

END USER : DUQM REFINERY

PROJECT : DUQM REFINERY PROJECT EPC1

: MECHANICAL AND E&I ERECTION OF HCU HEATERS

JOB
(03NOS)

CLIENT : TECNICAS REUNIDAS LLC

MANUFACTURER : ELCO INTERNATIONAL ENGINEERING CO LLC

P.O. NO. : 3316825260

ELCO JOB NO : JI-1060

1060

REVISION STATUS

01 21-05-2020 ISSUED
D FOR APPROVAL PRAVEEN KUMAR S ABDUL SAMIR
PREPARED BY APPROVED BY APPROVED BY
REV DATE DISCRIPTION
WE QCM CLIENT

Page 1 of 6
 WELD REPAIR PROCEDURE

TABLE OF CONTENTS

SR.NO DESCRIPTION PAGE

1.0 PURPOSE 3
2.0 REFERENCES 3
3.0 DEFINITIONS 3
4.0 MANPOWER & EQUIPMENT 3

5.0 REPAIR PROCEDURE 4

6.0 RECORDS 6
ATTACHMENT-01-- GENERAL FABRICATION & INSPECTION
7
REPORT
ATTACHMENT-02-- WELD TRACEABILITY & INSPECTION
8
REPORT
ATTACHMENT-03-- NDT REPORT 9

ATTACHMENT-04-- REPAIR LOG 10

Page 2 of 6
 WELD REPAIR PROCEDURE

1. PURPOSE

The purpose of this method statement is to define a documented methodology for the repair of welds and
to ensure that weld repairs are executed in accordance with project requirements and standards.
2. REFERENCES

ASME B31.3 Edition 2018

ASME Sec IX Edition 2019

ASME Sec II Part ‘C’ 2017 Edition – Specification for Welding Rods, Electrodes & Filler Wire Latest Edition.

DRP001-PUC-SPE-W-000-006 -Welding & NDE of pressure Equipment & Piping.

3. DEFINTIONS

Company : Duqm Refinery

Refi & Petrochemical Industries
A party, who places the order on, or requests tender from, the Vendor/
Supplier.
Contractor : TECNICAS REUNIDAS LLC
Person(s) appointed by the Company pursuant to the EPC Contract(s) to carry out the
Works.
Sub-Contractor : ELCO International Engineering Co. L.L.C.
A party responsible for the supply of equipment, materials or product related services
Specification and its referenced standards and data sheets.
in accordance with this Specification
LPT : Liquid Penetrant Test Report.

MPT : Magnetic Particle Examination.

4. MANPOWER AND EQUIPMENT

4.1. FOLLOWING PERSONNEL SHALL BE INVOLVED IN THE EXECUTION OF REPAIRS

Supervisor/Charge Hand

QC Inspector

NDE Personnel

Welder

Grinder Man

Page 3 of 6
 WELD REPAIR PROCEDURE

4.2. EQUIPMENT/TOOLS

Welding Machine

Grinding Machines,

Air
ir carbon arc gouging,

Grinding Wheels, Chisels, Blades, Wire Brushes etc
etc.

5. REPAIR PROCEDURE

The repair weld shall be made by using approved same original WPS only one time at same
location and qualified welders in accordance with code of construction and applicable client
specifications.

Repair preparation, remedial grinding and repair welding shall not commence before informing
the Company/ Contractor
ontractor QA/QC Technical Authority (TA). Repair Log shall be maintained.
DEFECT REMOVAL

When production welding repairs exceed 5% per month a root cause analysis (RCA) shall be
conducted and reported to the Welding Technical Authority (TA). For piping, the rejection rate
shall be on joint basis.

For equipment rejection rate is based on the total linear weld distance on a per-metre
per basis. A
rejection is considered to be any weld that requires a repair within a one-metre
one segment. The
rejection rate will be defined as the number of repair segments per total number of one-metre
one
segments.

Defect

Page 4 of 6
 WELD REPAIR PROCEDURE

Unacceptable defects in welds shall be excavated by machining or by grinding or by carbon arc

gauging followed by grinding to bright metal. Unacceptable defects in non-ferrous
non welds shall be
excavated by machining or grinding only. For full penetration weld repair root
r opening shall be
done by hacksaw blade.

The excavation shall be contoured to permit proper access for welding. For visual inspection or
dimensional checks, PT surface inspection techniques shall be used to confirm removal of welds
defects. Materials that require preheat
preheat for welding will require adequate preheat for defect
removal.
METHOD OF EXCAVATION OF REPAIR WELDS

Adjacent sides of repair shall be gradual taper.

Groove shall be free from scale and smooth contour. The excavation shall be contoured to permit
proper access for welding
welding.

Excavated area to be examined by V
Visual inspection and then by PT.

Repair weld Preheat shall consider larger heat sink. (As
( repair area is very small).

When complete removal of the defective weld metal is required, it sh
shall be at least 5 mm
including HAZ & Parent metal on each side.
NDE OF EXCAVATED AREA

Prior to start of re-welding,
lding, Visual inspection and PT shall be carried out to ensure complete
defect removal.
RE-WELDING

Once defect removal is ensured by applicable NDE method, re-welding
welding shall be carried out by
qualified
ied welders as per approved WPS only one time at the same location. Repair welding for a
second attempt to repairs shall be performed with approved Repair WPS/PQR. The repair WPS
shall be qualified in accordance
ac with the specification. The Qualification shall require the
reproduction of a typical production repair. Full penetration and partial penetration excavations
shall be qualified separately. The acceptance criteria for mechanical testing and corrosion
corrosi testing
(if required) of repair welds shall be the same as for the original weld. The repair WPS shall be
supported by appropriate PQR.
PQR All the repairs shall be done with GTAW/SMAW process.
NDE AFTER RE-WELDING

All repair welds are to be 100
100% re-inspected
inspected by the methods specified for the original weld and
shall extend a minimum of 50 mm beyond either side of the repair. Visual, PT/MT and
volumetric inspection (RT)
RT) or NDE used for original weld shall be done after re-welding.
re

Page 5 of 6
 WELD REPAIR PROCEDURE

REPAIR LIMITATIONS

When cracks are observed, the cause shall be investigated. When crack
crack/Base material defects
are observed, specific repair procedure shall be approved by company Welding TA.

Weld bevel restoration by welding is not permitted.

For partial penetration repairs on circumferential welds, the total length of excavation shall not
exceed 30 % of the weld length. For full penetration repairs, the total length of excavation shall
not exceed 20 % of the weld length.
length

The Min. Length of Repair shall be 50mm and shall be separated by 200mm wherever possible.

Butt Welds of size 2" & below shall not be repaired; the welds shall be cut & re
re-welded.

Arc Strikes outside the groove shall be ground smooth and examined by PT & Thickness checked
in case of possible thickness reduction.
reduct

Weld repair / Instruction report from welding engineer to production is required for each repair
supported with RT tracings / UT depth readings in case of partial repairs.

The repair joint identification shall be R1-
R1 repair weld, RW- cut out and re-weld,
re R2- second time
repair and so on.

For major repair and for repair occurred after PWHT NCR shall be raised and prior approval
from company QA/QC, shall be obtained before proceeding with repair welding.
6. RECORDS

Attachment-01-General fabrication & Inspection Report.

Attachment-02-Weld
Weld Traceability
Tra & Inspection Report.

Attachment-03-NDT
NDT Report.
Report

Attachment-04-Repair
Repair Log.
Log

Page 6 of 6
 GENERAL FABRICATION & INSPECTION REPORT
CLIENT : QCF 3.12 C Rev 0
MAIN CONTRACTOR : Report No :
JOB TITLE : Date :
PROJECT :
CONTRACT NO :
ELCO JOB No :
Welding Dimensional Visual
SI.No Drawing No Item No Qty Heat No Weld No Thk / Sch WPS No Fit-up Welder No MPI A/R UT A/R Remarks
Date Inspection Inspection

ELCO INTERNATIONAL MAIN CONTRACTOR CLIENT

NAME : NAME : NAME :

DESIGNATION : DESIGNATION : DESIGNATION :

SIGNATURE : SIGNATURE : SIGNATURE:

DATE : DATE : DATE :

1 OF 1
 QCF-3.13 Rev.0
ELCO INTERNATIONAL ENGINEERING Co.LLC
P.O.Box:3353, P C :111, CPO SEEB, Sultanate of Oman
Ph:+968 24698313, Fax: +968 24698323, E.Mail: ho@omanelco.com

WELD TRACEABILITY AND INSPECTION REPORT

Contract Title : Job Description :
ELCO Ref No. : P.O.No.
Area/Location : ELCO WORKS
NDT Reports PWHT
Sl Size & Sch / Material Spec / Date of NDE Reports
Drawing No. / Line No. Weld No. Type Welder No WPS No Visual (Repair welding) Report Remarks
No. Thk Identification welding
RT PT/MT UT RT PT/MT (if any)

Inspector's Name:- TPI :- Client:-

Signature/date Signature/date Signature/date

 LIQUID PENETRANT EXAMINATION TEST REPORT

REPORT NO.: DATE

CLIENT
CONTRACTOR
SUB CONTRACTOR
CONTRACT NO.:
Approved Drg. No Rev.;
ITP REF. NO.: Rev.
PROCEDURE NO Rev.
REF. CODE
ACCEPTANCE CRITERIA EXTENT OF EXAMINATION
MATERIAL EXAMINATION STAGE : WITNESS
Weld No Welder No Size Sch/WT Observation Result
PENETRANT TYPE
PENETRANT SYSTEM

CLEANER PENETRANT DEVELOPER

Make : Make : Make :
Batch No.: Batch No.: Batch No.:
Date : Date : Date :
Validity : Validity : Validity :
SURFACE CONDITION
PENETRANT DWELL TIME – Weld Type
DRYING TIME - LIGHT EQUIP.
DEVELOPING /DWELL TIME
Test Date Test Time
Weld No Welder No Size Sch/WT Observation Result

Elco International Engg. Co. LLC TPI /Client TPI /Client

Sign Sign: Sign

Name : Name : Name :

Date: Date: Date:
 QCF 5.31 Rev00
ELCO INTERNATIONAL ENGINEERING Co.LLC
P.O.Box:3353, P C :111, CPO SEEB, , Sultanate of Oman
Ph:+968 97055110, Fax: +968 24503120, E.Mail:ho@omanelco.com

REPAIR LOG
Contract Title : Job Description :
ELCO Ref No. : P.O.No.
Area/Location : ELCO WORKS
SI Drawing No. / Weld /Joint Type Size & Date of Welder WPS NDE Reports NDT Reports Remarks
Oreintation Location Repair Type Repair Length
No Line No. No Sch./Thk. Welding No No (Before Welding) (After Welding)
RT PT/MT UT RT PT/MT

ELCO INTERNATIONAL ENGINEERING CO LLC MAIN CONTRACTOR CLIENT

Name Name Name
Designation Designation Designation
Signature/date Signature/date Signature/date