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DESCRIPTION
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CHK
APP
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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 5.2.2 5.2.3 5.2.4 The remaining weld thickness of section is not below them that minimum wall thickness of material. The depression, after defect elimination is blended uniformly into the surrounding surface. 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. 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: Pipe/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 requirement, tapered welding shall be carried out for gradual change in thickness (ref ANSI/ASME B 5.4.1
Case a
Case b 5.4.2 5.4.3 5.4.4 Internal repair welding shall be carried out only on above 24 diameter piping. Root repair on less than 2 pipe shall be a cut out. Any welds containing cracks or suspected cracks shall be cutout. 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 shall be performed in accordance with the WPD of the initial weld.
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.