Information Source: Approved:

Supervisor Manager ( Steel/Outfitting )

( Steel/Outfitting )

Work Instruction – Steel / Outfitting

Date: Nov 2019 Edition No: 2 Page No: 1 of 9 Rev 5 PT. Graha Trisaka Industri
PT. Dok Warisan Pertama
Intranet copy is approved and Controlled, Uncontrolled if printed.
PT. Nanindah Pertama Shipyard
Title: Weld Repair and Buttering Procedure DS-003

1. Purpose
The purpose of this procedure is to repair of base material defects, weld defects and buttering of
large gaps encountered during structural fabrication.

2. Scope
This procedure provides the guidelines for repair of base material defects, weld defects and
buttering of large gap joints. All repairs made by welding must be according to qualified WPS AWS
D1.1 for the base materials intended to repair.

3. Definition
1.1 NDT Non-Destructive Testing
4.2 MPI Magnetic Particle Inspection
4.3 DPI Dye Penetrant Inspection
4.4 WPS Welding Procedure Specification
4.5 CJP Complete joint penetration

4. Procedure

Note: Before starting any work, all personnel involved must be aware of the control measures
stated in the relevant HSE risk assessments. It is the responsibility of the supervisor to ensure that
the control measure stated in the HSE Risk Assessments are maintained and/or implemented.

4.1 Responsibility
Supervisor Steel/Outfitting

4.2. Repairs
All unacceptable discontinuities identified by visual, dimensional and non-destructive
examinations shall be considered as defect and repair is required. Repairs are classified
in to the following types.

4.2.1 Weld Repairs

All unacceptable discontinuities such as undercuts, overlaps, under filling,
excessive convexity, excessive reinforcements, lack of fusion, incomplete
penetration, porosity, slag inclusions and cracks are considered as weld
defects. All weld defects shall be rectified as per guidelines given in Section 4.3
(Removal and Repair of Weld Defects).

4.2.2 Base Metal Repairs

All minor base metal defects such as arc burns, metal overlaps, surface
imperfections, gas cutting notches, are considered as minor base metal repairs.
All base metal repairs shall be rectified in accordance with respective material
specifications and guidelines given in Section 4.4 (Repair of Base Metals).
Information Source: Approved:
Supervisor Manager ( Steel/Outfitting )
( Steel/Outfitting )

Work Instruction – Steel / Outfitting

Date: Nov 2019 Edition No: 2 Page No: 2 of 9 Rev 5 PT. Graha Trisaka Industri
PT. Dok Warisan Pertama
Intranet copy is approved and Controlled, Uncontrolled if printed.
PT. Nanindah Pertama Shipyard
Title: Weld Repair and Buttering Procedure DS-003

4.2.3 Buttering
All unacceptable joint fit ups due to excessive gaps shall be considered for
rectification by buttering on bevel edges to obtain gaps suitable for welding or
providing temporary backing strips of some base metal. All joint fit ups to be
buttered shall be carried out in accordance with guidelines given in Section 4.5
(Buttering).

4.3 Removal and Repair of Weld Defects

All minor weld defects such as arc strikes, undercuts, overlaps, excessive convexity, and
excessive reinforcements shall be repaired by light grinding without reducing minimum wall
thickness unless it calls for welding to fill undercuts or under flush due to removal of surface
porosity. If required to deposit weld metal, the same shall be done in accordance with WPS
originally used for the joint.

4.3.1 All other unacceptable weld metal defects such as cracks, subsurface porosity, slag
inclusions, lack of fusion, and lack of penetration in weld joints shall be removed by
air carbon arc gouging or grinding. The defect portion of weld metal only shall be
removed without removal of substantial adjacent sound metal. In the case of crack,
the specific repair sequence shall be made and get it reviewed by Head of
QA/Commissioning prior to start of repair.

4.3.2 The following repair sequence shall be as follows:

4.3.2.1 Identify the location and magnitude of each defect and mark directly over
the defect for its entire length with the help of NDT reports.

4.3.2.2 The defect shall be removed by air carbon arc gouging or grinding. Welding
Foreman shall monitor removal process to ensure the complete removal of
defect. Refer (Figure 1) for typical sketches shown for removal of defects
from original welds and repair welds.

4.3.2.3 Carry out MPI/DPI to ensure defect free.

4.3.2.4 Preheat and inter pass temperature for all welding repair shall be done in
accordance with approved WPS. The qualified welders only shall perform
repair welds.

4.3.2.5 The repaired welds shall be re-examined by the some type of NDT method
and acceptance criteria used for original welds. The weld joint shall be
considered acceptable after weld repairs are cleared from NDT.

4.3.2.6 If the repair is not successful, re-repair should be carried out using same
above sequence.
Information Source: Approved:
Supervisor Manager ( Steel/Outfitting )
( Steel/Outfitting )

Work Instruction – Steel / Outfitting

Date: Nov 2019 Edition No: 2 Page No: 3 of 9 Rev 5 PT. Graha Trisaka Industri
PT. Dok Warisan Pertama
Intranet copy is approved and Controlled, Uncontrolled if printed.
PT. Nanindah Pertama Shipyard
Title: Weld Repair and Buttering Procedure DS-003

4.4 Repair of Base Metals

4.4.1 All unacceptable base metal defects such as arc burns (arc strikes),metal overlaps,
surface imperfections, gas cutting notches shall be ground to remove mill scales
before carrying out any repair. Grind the arc burns area with a disc grinder until
evidence of the arc burn is no longer visible to the naked eye and carry out MPI or
DPI and ensure that no defect left. If thickness of plate reduced beyond acceptable
limits, the area shall be restored by weld deposit as per qualified WPS.

4.4.2 All cracks and lamination defects shall be repaired with specific procedure made.

4.4.3 Prior to repair of any crack, ascertain the exact length of crack by using MPI or DPI.
The cracks shall be removed 25mm beyond each end of the crack.

4.4.4 All repairs welding shall be done by using qualified WPS for base material on butt
joint. The qualified welders for butt joint shall be employed for repair welding.

4.4.5 Carry out MPI or DPI on all repair welds. If repair depth is greater than 12.5% of
wall thickness, the repair spot shall be tested by UT or RT.

4.5 Buttering

4.5.1 All unacceptable joint fit ups due to excessive gaps shall be buttered on one of
bevel edge using stringer bead technique as per sketches shown in (Figure 4)
reference point or datum line is laid out from edge of the material. From this point
the extent of buttering is measured. If large gaps observed in square butt joints
used by SAW process, the large gaps shall be welded with seal pass using
qualified SMAW process for the base material prior to start of SAW.

4.5.2 All buttering welds shall be done by using approved WPS including pre-heat and
inter pass temperature. The qualified welder on butt joint for the process shall be
employed for all buttering on base metals. Buttering should be carried out with 2.6
or 3.2 mm dia, of electrodes as per approved WPS. The buttered surface may be
ground to remove high points before actual joint welding.

4.5.3 QA/Commissioning Inspector shall inspect visual examination on all buttered welds
surfaces before proceeding the final welding. The final weldment of joints buttered
shall be inspected 100% MPI and UT/RT as required by NDT Matrix.

4.6 Safety and Precaution

4.6.1 Welders are required to wear the suitable Personal Protective Equipment (PPE)
during all welding operations.

4.6.2 The weld repair area shall be protected from wind and rain

4.6.3 The condition of the welding equipment and cables shall be checked by the welding
foreman prior to start of any repair welding.
Information Source: Approved:
Supervisor Manager ( Steel/Outfitting )
( Steel/Outfitting )

Work Instruction – Steel / Outfitting

Date: Nov 2019 Edition No: 2 Page No: 4 of 9 Rev 5 PT. Graha Trisaka Industri
PT. Dok Warisan Pertama
Intranet copy is approved and Controlled, Uncontrolled if printed.
PT. Nanindah Pertama Shipyard
Title: Weld Repair and Buttering Procedure DS-003

4.6.4 Ensure welding machines are well earthed before start of welding operation.

4.6.5 Ensure preheating should be carried out using pre-heating burners. Using of gas
cutting torches for pre-heating are prohibited.

4.6.6 Use extractor system for ventilation when welding in confined space or when
excess fumes are generated.

4.6.7 Remove surface coating from areas to be welded.

4.7 General

This procedure shall be used as a guideline for repair of weld defects, base metal defects,
and restoration of base metals and weld metal buttering on weld edges for joints having
excessive gaps. Defects shall be located based on the results of visual inspection,
dimensional and NDT methods

4.7.1 Each repair at site shall be reviewed on case to case basis prior to commencement
of actual repair or rectification work. Any repair or rectification work to be carried out
shall be proposed by production department to QA/Commissioning. If the repairs
are serious nature like cracks, restoration base materials, the buttering of large
gaps intended to weld as CJP from single side, the specific repair sequence shall
be made and get it reviewed by Head of QA/Commissioning. The rectification of any
crack or lamination is subjected to approve of owner’s representative and Class
Surveyor.

4.7.2 The welding of all repairs shall be carried out as per qualified WPS for original
welding. The qualified WPS for SMAW/FCAW-GS process may be used for
repairing weld metal that originally deposited by SAW process.

4.7.3 The repaired weld metal shall be retested by the NDT method originally used
including acceptance criteria.

4.7.4 Defect location including length shall be laid out on weldment. The detail of
excavation of groove shall be as per sketches given in (Figure 2) Groove angle and
radius shall be verified using template detail as per sketch given in (Figure 3).
Information Source: Approved:
Supervisor Manager ( Steel/Outfitting )
( Steel/Outfitting )

Work Instruction – Steel / Outfitting

Date: Nov 2019 Edition No: 2 Page No: 5 of 9 Rev 5 PT. Graha Trisaka Industri
PT. Dok Warisan Pertama
Intranet copy is approved and Controlled, Uncontrolled if printed.
PT. Nanindah Pertama Shipyard
Title: Weld Repair and Buttering Procedure DS-003

WELD REPAIR SKETCHES FOR STRUCTURE

(Figure 1)
TYPICAL SKETCHES SHOWING REMOVAL AND REPAIR OF WELD DEFECTS

(Figure 2)

SKETCH FOR REMOVING THE DEFECT

Information Source: Approved:
Supervisor Manager ( Steel/Outfitting )
( Steel/Outfitting )

Work Instruction – Steel / Outfitting

Date: Nov 2019 Edition No: 2 Page No: 6 of 9 Rev 5 PT. Graha Trisaka Industri
PT. Dok Warisan Pertama
Intranet copy is approved and Controlled, Uncontrolled if printed.
PT. Nanindah Pertama Shipyard
Title: Weld Repair and Buttering Procedure DS-003

(Figure 3)
Information Source: Approved:
Supervisor Manager ( Steel/Outfitting )
( Steel/Outfitting )

Work Instruction – Steel / Outfitting

Date: Nov 2019 Edition No: 2 Page No: 7 of 9 Rev 5 PT. Graha Trisaka Industri
PT. Dok Warisan Pertama
Intranet copy is approved and Controlled, Uncontrolled if printed.
PT. Nanindah Pertama Shipyard
Title: Weld Repair and Buttering Procedure DS-003

(Figure 4)
A) TYPICAL ‘T’ CONNECTION WELD PLATE EDGE PREPARATION REPAIR
Information Source: Approved:
Supervisor Manager ( Steel/Outfitting )
( Steel/Outfitting )

Work Instruction – Steel / Outfitting

Date: Nov 2019 Edition No: 2 Page No: 8 of 9 Rev 5 PT. Graha Trisaka Industri
PT. Dok Warisan Pertama
Intranet copy is approved and Controlled, Uncontrolled if printed.
PT. Nanindah Pertama Shipyard
Title: Weld Repair and Buttering Procedure DS-003

C) TYPICAL BUTT WELD PLATE EDGE PREPARATION REPAIR

D) TYPICAL FILLET WELD PLATE EDGE PREPARATION REPAIR

If Gap 5mm-16mm,Chamfer to 30°-45°,build up with welding, on one side, with or without backing
strip, grind and weld.
Information Source: Approved:
Supervisor Manager ( Steel/Outfitting )
( Steel/Outfitting )

Work Instruction – Steel / Outfitting

Date: Nov 2019 Edition No: 2 Page No: 9 of 9 Rev 5 PT. Graha Trisaka Industri
PT. Dok Warisan Pertama
Intranet copy is approved and Controlled, Uncontrolled if printed.
PT. Nanindah Pertama Shipyard
Title: Weld Repair and Buttering Procedure DS-003

5. Reference

5.1 AWS D1.1 * : Structural Welding Code-Steel

5.2 American Bureau of Shipping Rules.
* Code or Standard revision in use as at time of signing contract

6. Form & Records

6.1 Requisition For Inspection (DQA-005-001)

6.2 Magnetic Particle Test Report (DQA-004-002)
6.3 Dye Penetrant Test Report (DQA-004-003)
6.4 Ultrasonic Test Report (DQA-004-004)
6.5 RT Test Reports