GENERAL REPAIR PROCEDURE

Document No: STD-INSP-0016

A 30-05-2022 FIRST ISSUE

Prepare Reviewe Approve
Re AI/TPI/
Date Details d d d
v CLIENT
By By By QM
PROCEDURE NO STD-INSP-0016 REV. No. A Page 2 of 3
GENERALREPAIR PROCCEDURE

1. Scope:
1.1 This procedure covers the minimum requirements for repairs (minor & major) that may
be necessitated on materials and weldments.

2. Responsibility:

2.1 Quality Manager

2.2 Inspection Engineer

2.3 Welding Engineer / Welding Inspector.

2.4 Production Manager / Production Engineer

3. Reference:

2.1 ASME Section VIII Div. 1 & 2

2.2 ASME Section 1

2.3 ASME Sec. IX

(Latest Edition and Addenda on the day of use of this procedure)

2.4 Client Specification

4. Weld Repair – Definitions:

3.1 MINOR WELD REPAIR– is defined as porosity, undercut, slag inclusions, arc strikes,
inclusions & repair cavity less than 20% of metal thickness.

3.2 MAJOR WELD AND BASE METAL REPAIR – Major weld and base metal repairs are defined
as cracks, lack of fusion, lack of penetration, a repair cavity greater than 10 square
inches, repair cavity greater than 20% of metal thickness, weld buildup to correct
manufacturing error, edge defects greater than 25 mm. in length and all hydro test
leakages.

5. Procedure:

4.1 Welding Inspector shall be responsible for preparation of procedure and monitoring repair
and NDE activities.

4.2 NCR shall be raised for the base metal repairs.

4.3 In case of major repair, procedure shall be submitted to Authorized Inspector for review
and Client for approval. Major defects shall not be repaired until a written procedure for
each individual repair has been reviewed and accepted.

4.4 Base metal and weld repairs shall be made with same type of welding consumables using
welding procedures already approved by Client / AI.

4.5 All base metal and welding repair shall be performed by qualified welders only.

4.6 The defects shall be removed either by:

a) Grinding

b) Air-arc gouging and grinding to clean

c) Chipping and grinding

PROCEDURE NO STD-INSP-0016 REV. No. A Page 3 of 3
GENERALREPAIR PROCCEDURE

4.7 Prior to the commencement of the repair welding, the defective area shall be checked
either by visual and MT or PT to ensure that no defect are left.

4.8 Repair welding shall be done in accordance with the WPS used to weld the original weld,

4.9 except when the original weld was welded with SAW (Submerged Arc Welding). In that
case, the repair may be performed in accordance with an approved WPS for SMAW which
covers the essential variables for the base material welded.

4.10 For the repair welding on material thickness ≤ 25 mm. and the original weld did not require pre-heat, the preheat
of 100°C min. shall be applied

4.11 Upon completion of the repair, the welded area shall be cleaned and dressed by grinding
and submitted for NDE examination where applicable. NDE shall be original testing
method as a minimum.

4.12 Repairs performed on weld, which do not require NDE testing shall be checked by MT or
PT depending upon the type of base material.

4.13 If major welding repairs revealed during non-destructive examination, the repair WPS
shall require Client approval and shall include the following;

4.14 The welds may be repaired twice at any defect location.

4.15 If a weld is still not acceptable after the second repair, then Client / Inspection has the
sole authority for the decision to permit additional repair attempts or to require that the
entire weld be cut out.

4.16 If weld repair is performed after PWHT then separate method statement shall per
prepared including PWHT required or not and submitted to Client and AI prior to repair.

6. Documentation

6.1 After successful completion of the weld repairs, the report shall be prepared and signed
by the Welding Inspector and presented to the Client / AI inspector for review.