YANBU II POWER & WATER PROJECT

PACKAGE: 3

REPAIR WELDING PROCEDURE FOR PIPE

Document No. :
Revision :
Date of Issue :
 YANBU II POWER &
WATER PROJECT
Contract PO No.: REPAIR WELDING Date of Issue:28/03/2012
Doc No. : PROCEDURE FOR
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Rev No. : PIPE

REPAIR WELDING PROCEDURE FOR PIPE

Document No. :

Project Name : YANBU II POWER & WATER PROJECT

Contract No. :

Client :

EPIC CONTRACTOR

Rev Date Description Prepared by Reviewed by Approved by

 YANBU II POWER &
WATER PROJECT
Contract PO No.: REPAIR WELDING Date of Issue:28/03/2012
Doc No. : PROCEDURE FOR
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Rev No. : PIPE

Plant : Document No. : Rev.

Title :

REPAIR WELDING PROCEDURE FOR PIPE

REV. DATE DESCRIPTION BY CHK APP

Project :

Project Co. :

EPC Contractor :
 YANBU II POWER &
WATER PROJECT
Contract PO No.: REPAIR WELDING Date of Issue:28/03/2012
Doc No. : PROCEDURE FOR
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Rev No. : PIPE

TABLE OF CONTENTS

1.0 SCOPE

2.0 DEFINITION OF TERMS

3.0 REFERENCE DOCUMENTS

4.0 RESPONSIBILITIES

5.0 PROCEDURE
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WATER PROJECT
Contract PO No.: REPAIR WELDING Date of Issue:28/03/2012
Doc No. : PROCEDURE FOR
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Rev No. : PIPE

1.0 SCOPE
This procedure applies to all repairs and out of specification misalignment problem that become
apparent with certain fittings such as large diameter T and bends when joining same diameter and
thickness of fittings to pipe.

2.0 DEFINITIONS
ASME - American Society of Mechanical Engineers
NDE/NDT - Non Destructive Examination/Testing.
ANSI - American Nation Standard Institute.
WPS - Welding procedure Specification.

3.0 REFERENCE DOCUMENTS

ANSI/ASME B31.3 Process piping
ASME B16.25 Butt welding Ends.

4.0 RESPONSIBILITIES
The Construction manager shall be responsible for the implementation of weld repair while responsibility
of the QA/QC manager is to examine, to issue a repair authorization report and to perform NDT on weld
parts repaired.

5.0 PROCEDURE

5.1 Minor defects found in intermediate/final passes of the weld joints visually or by NDT and other
testing shall be removed only by grinding or machining.

5.2 Repair by welding is not required on the base material when the following requirements are met:

5.2.1 The remaining weld thickness of section is not below them that minimum wall thickness
of material.
5.2.2 The depression, after defect elimination is blended uniformly into the surrounding
surface.
5.2.3 The area shall be examined by visual check after blending and meets the acceptable
standards to ensure that the defect has been removed or reduced to acceptable limit
magnetic particle inspection (MPI) or DPI methods will be applied only when necessary.
5.2.4 Defect removal area that does not meet the requirement of relevant specification and
the procedure must be repaired by welding .The welding repair shall be made using
welding material, welders, and welding procedure qualified for the original weld. Any
changes in process require re-qualification welding procedure shall apply during and
after repair of welding.

5.3 Repair surface shall be blended uniformly into the surrounding surfaces and tapered at sides and
ends as per American National Standard Institute.

5.4 Weld repairs are limited to the following:

5.4.1Pipe/pipe spool repairs are classified in two cases

Case (a): Mismatch of outer diameter (OD).
Case (b): Mismatch of internal diameter (ID).
Case (a): When external misalignment is noted and weld cap reinforcement is not sufficient to the
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Contract PO No.: REPAIR WELDING Date of Issue:28/03/2012
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requirement, tapered welding shall be carried out for gradual change in thickness (ref ANSI/ASME B
16.25).

Case (b): Chamfering and tolerance of the internal diameter shall be maintained as per ASME 31.3 that
is about 1.6mm, But in the case that is above 1.6mm,either weld deposition will be carried out at the
thinner area, or taper grinding at thicker section with care shall be taken (reduction will not be more than
12.5% nominal wall thickness) ,(ii) degree of taper grinding should be as per ratio of 1:3 ASME 31.3 ,
thickness check will be carried out to ascertain wall thickness of the spool.

Repair welding shall be performed by buildup welding in case of thickness reduction.

Case a

Case b

5.4.2 Internal repair welding shall be carried out only on above 24” diameter piping.
5.4.3 Root repair on less than 2” pipe shall be a cut out. Any welds containing cracks or
suspected cracks shall be cutout.
5.4.4 Where accessible to perform grinding and welding at the pipe inside, the internal root
weld defects shall be removed by grinding after SPDC inspection. Its repair welding
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Contract PO No.: REPAIR WELDING Date of Issue:28/03/2012
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Rev No. : PIPE

shall be performed in accordance with the WPD of the initial weld.

5.4.5 External root repair are limited to 50% of circumference
5.4.6 Minimum repair length is 50mm and must be tapered.

5.5 Defective welding shall be identified and recorded by one or more of the following when applicable:
 Visual Inspection
 Magnetic Test
 Radiographic Examination
 Dye Penetration Test

5.6 Any repair welding dates shall be recorded by welding supervisor at site or shop .All Repairs welding
used in this procedure will be subjected to visual inspection or radiography and any other NDT
methods as required.

5.7 NDE report shall include the following information:

 Line number
 Line Size
 Weld Number
 Date
 Type of defect
 Size of detect

5.8 NDE report shall be handed over to the welding supervisor and welder with a briefing by the NDE
Technician to identify the exact location and type of the defect.

5.9 The NDE Technician will accurately mark the weld to identify the location of the defect using indelible
crayon marker.

5.10 Defective weld length shall be carefully removed by grinding. Boat shaped weld fill space shall
ensure sufficient run in/run out appropriate to the repair length with the relevant WPS.

5.11 The pre heating /PWHT of welding shall be performed as stated in applicable WPS

5.12 PWHT weld joint which failed RT, shall undergo weld repair followed with subsequent RE-PWHT
and RT accordingly.

5.13 Welding shall be done by an experienced, qualified welder; there shall be two of such welders
qualified for each or both applicable procedure.