PAGE

1 of 10

Standard Operating Procedure

 DOCUMENT NO. :
Weld Repair W-QC-A-006
Control Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 2 of 10 1

ORIGINATOR ACCEPTED BY REVIEWED BY DISTRIBUTION

Master : CDCC

Copy : ENG

Copy : MC
Irsyafriandi Yanferizal
Welding Engineer QC. Manager Authorized Inspector Copy : PDCC
ISSUED EFFECTIVE
REV. NO BRIEF OF REVISION
DATE DATE Copy : PM
Change of Company Name from
1 26/11/07 26/11/07 PT. Truba Jaya Engineering to PT. Copy : PROD
Truba Jaya Engineering

Copy : PROC

Copy : QC

Copy : SM
W-QC-A-001.E4

TABLE OF CONTENT

No. Descriptions Page

COVER PAGE 1 of 9

TABLE OF CONTENT 2 of 9

1 TITLE 3 of 9

2 SCOPE 3 of 9

3 REFERENCES 3 of 9
4 RESPONSIBILITY 3 of 9

Second Edition
 DOCUMENT NO. :
Weld Repair W-QC-A-006
Control Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 3 of 10 1

5 DEFINITION 3 of 9
5.1. Major Defects 3 of 9
5.2. Minor Defects 4 of 9
6 DESCRIPTION OF PROCEDURE 4 of 9
6.1. Repair Procedure for Major Defects 4 of 9
6.1.1. Welding Repair Step 4 of 9
6.1.2. Welding Repair After PWHT for Section I 5 of 9
6.2. Repair Procedure for Minor Defects 8 of 9
7 LIST OF EXHIBIT 8 of 9
7.1. EXHIBIT 1 : NDE Tracing/Reader Sheet 9 of 9

1.0. TITLE
Weld Repair Control Procedure

2.0. SCOPE
The procedure describes the system of controlling the repair of weld
defects during the construction of Boiler, Boiler External Piping at the
Company’s shop or at field sites.

3.0. REFERENCE
3.1. QC Manual, Doc. No. M-A-001
3.2. ASME Section I, applicable year Edition and Addenda
3.3. ASME Section IX, applicable year Edition and Addenda
3.4. ASME/ANSI B31.1, Power Piping, applicable year Edition and Addenda

Second Edition
 DOCUMENT NO. :
Weld Repair W-QC-A-006
Control Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 4 of 10 1

4.0. RESPONSIBILITY
4.1. Any repair work of major defects shall be done under the surveillance of
both Welding Supervisor & QC. Inspector with concurrence of AI and
Welding Engineer.
4.2. The Minor defects may be repaired under the control of QC. Inspector
and Welding Supervisor. All responsibility of control of the major defects
shall be of the Welding Engineer.

5.0. DEFINITION
5.1. Major Defects
The following defects shall be classified as Major defects:
a. All cracks that sustained in weld metal extend into parent material.
b. Large volume of material defect, which required welding repair.
c. Unacceptable defects detected by the Nondestructive test such as
crack that not extend to parent material, porosity, lack of fusion, and
lack of penetration, slag inclusion, arc strike, etc. which in size
exceeds the allowable permitted by related Code section.
d. Any repair that involves welding after final post weld heat treatment.
e. Any weld leakage detected during Hydrostatic or Pneumatic test
5.1.1. All major repair shall be considered as a nonconformity, however this
typical of nonconformity may not be subjected in rising of a “NON
CONFORMITY REPORT“. This may be modified by reporting this defect in
detail on “NDE TRACING/READER SHEET“ (Exhibit 1)

5.1.2. The NDE Practitioners shall be responsible for preparing the NDE – Repair
Tracing/Reader Sheet, of which shall accompany the NDE Report and
Defect Tracing.

a. If the finding is classified as Major defects, the NDE Tracing/Reader

Sheet plus all attached documents should be reviewed by parties
concerned for their concurrence and judgment/recommendation.

b. Upon satisfactory repair and examination of repaired weld defect the

Authorized Inspector shall close out the NDE Tracing/Reader Sheet.

5.2. Minor Defects

All defects other than those classified in para 5.1 should be considered as
minor defects such as:

Second Edition
 DOCUMENT NO. :
Weld Repair W-QC-A-006
Control Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 5 of 10 1

a. Surface irregularities, which are eliminated by surface grinding and/or

dressing.
b. Weld defects found during the course of welding which can be
immediately corrected such as undercut, excessive reinforcement,
overlapping, crater cracks, etc.

6.0. DESCRIPTION OF PROCEDURE

6.1. Repair Procedure For Major Defects
6.1.1. Welding Repair Steps
a. The NDE Reader Sheet shall be prepared and raised against any
major defects and submitted to Welding Supervisor for action and to
QC. Engineer, Welding Engineer and AI for their concurrence.
b. The Welding Qualification test for repair of the weld defects shall be
in accordance with ASME Section IX.
c. Weld defects that has been detected visually or by NDE and defects
detected by Leakage Test shall be removed by Mechanical Means or
by Thermal Gouging Process.
d. The area prepared for repair shall be examined by Magnetic Particle
Examination or Dye Penetrant Test to ensure that the defect have
been removed completely prior to commence with welding.
e. Only SMAW process should be used, except the original weld was
using GTAW process. In SMAW the electrode size to be used is
preferably smaller than that for the original weld, but no larger than
4.0 mm. Stringer bead shall be applied for each pass.

f. The weld areas after being gouge out shall be re-welded by qualified
welder using qualified WPS.
g. Repaired weld shall be re-examined by the original means of
examination of the weld, with an extend of at least 2 inch (50 mm)
on either ends. The repaired weld shall not be accepted and/or
released, unless the examination shown satisfactory.

6.1.2. Welding Repair After PWHT for Section I

6.1.2.1. Imperfections such as
cracks, pin-holes and incomplete fusion detected visually or by leakage
tests or by the examinations described in PW-11 and found to be
rejectable shall be removed by mechanical means or by thermal grooving
processes, after which the joint shall be re-welded and re-examined.

Second Edition
 DOCUMENT NO. :
Weld Repair W-QC-A-006
Control Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 6 of 10 1

6.1.2.2. The preheating and post

weld heat-treating rules shall apply to all weld repairs made to pressure
parts except as follows.
1. When tube-to-tube header or tube-to-drum welded joints
have already received by PWT-11 and PW-39, minor local additional
welding for rework of the joint or to improve the fillet weld contour
may be performed without repeating the Post Weld Heat Treatment
but the subject to the following requirements:
a. The dept of any rework welding below the surface
shall not exceed the smaller of 10% of the thickness of the drum
or header, or 50% of the wall thickness of the tube.
b. The area to be rework welded shall be preheated
to at least the minimum temperatures as indicated below for the
material:

Material Minimum Preheat, F

Welding P-Number Group for Rework Welding

P-No.1 200
P-No.3, Group 1 & 2 200
P-No.4 250
P-No.5 A 300

c. The tubes shall not exceed 4 in O.D except for P-

No.1 material, of which shall not exceed 6 5/8 in O.D.
d. The welding procedure used for rework welding
shall have been qualified to the requirements of Section IX for
the thickness of rework welding to be performed and for the
omission of Post Weld Heat Treatment.
6.1.2.3. Defect in P-No. 1 Group
Nos. 1, 2 and 3 materials, and P-No. 3 Group Nos. 1 and 2 materials, and
in the welds joining these materials, may be weld repaired after the final
PWHT but prior to the final hydrostatic test. The welded repairs shall
meet the requirements below.
6.1.2.3.1. Defect Removal
for Base Materials.
The defect shall be removed or reduced to an acceptable size. Before
repair welding, the groove shall be examined to verify that the defect
has been reduced to an acceptable size, using either the magnetic
particle or the liquid penetrant examination methods. When the material
is nonmagnetic, only the liquid penetrant method shall be used.

Second Edition
 DOCUMENT NO. :
Weld Repair W-QC-A-006
Control Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 7 of 10 1

Methods for magnetic particle examination and liquid penetrant

examination shall be in accordance with A-260 and A-270, respectively;
however, the acceptance standards for the examination shall be in
accordance with the requirements of the original base material
specification
6.1.2.3.2. Defect Removal
for Welds and Welded Repairs.
The defect shall be removed, and the groove examined to verify
defect removal, using either the magnetic particle or the liquid
penetrant examination methods. When the material is nonmagnetic,
only the liquid penetrant method shall be used. Methods and
acceptance standards for magnetic particle examination and liquid
penetrant examination shall be in accordance with A-260 or A-270,
respectively.
6.1.2.3.3. The total repair
depth shall not exceed 10% of the base material thickness. The total
depth of a weld repair shall be taken as the sum of the depths for
repairs made from both sides of a weld at a given location. The total
area of such repairs shall not exceed 100 in.2 (0.065 m2).
6.1.2.3.4. In addition to the
requirements of Section IX for qualification of welding procedure
specifications for groove welds, the following requirements shall apply:
(a) The weld procedure qualification shall have been made using
material of the same P-No. and Group No. as the material to be
repaired. The specific welding technique or combination of welding
techniques used shall have been developed and tested to assure
adequate tempering of the underlying weld bead heat-affected
zones.
(b) The weld metal shall be deposited by the manual shielded metal-
arc process. Only low hydrogen welding electrodes shall be used.
The electrodes shall be properly conditioned in accordance with
Section II, Part C, SFA 5.5, Appendix A6.11.

(c) The maximum heat input for each weld layer shall not exceed that
used in the procedure qualification test.
(d) The maximum deposited weld bead width for any electrode shall
be four times the electrode core diameter.
(e) The repaired area, including a band equal in width to 4 in. (100
mm) or four times the thickness of the weld repair, whichever is
greater, on either side of the groove, shall be preheated and

Second Edition
 DOCUMENT NO. :
Weld Repair W-QC-A-006
Control Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 8 of 10 1

maintained at a minimum temperature of 350oF (175°C) during

welding. The maximum interpass temperature shall be 450°F
(230°C).
(f) The repair weld method shall be limited to the half bead weld
repair technique as follows. The initial layer of weld metal shall be
deposited over the entire area using 1/8 in. (3 mm) maximum
diameter electrodes. Approximately one half the thickness of this
layer shall then be removed by grinding before depositing
subsequent layers. The subsequent weld layers shall be deposited
using 5/32 in. (4 mm) maximum diameter electrodes, in such a
manner as to assure tempering of the prior weld beads and their
heat affected zones. A final temper bead weld shall be applied to a
level above the surface being repaired without contacting the base
material, but close enough to the edge of the underlying weld
bead, to assure tempering of the base material heat affected
zone.
6.1.2.3.5. For materials greater
than 1 in. (25 mm) thick, after completing all welding, the repair area
shall be heated to and maintained at a temperature of 450°F to
550°F (230°C to 290°C) for a minimum period of 4 hr.
6.1.2.3.6. Any final temper
bead reinforcement shall then be removed substantially flush with the
surface of the base material.
6.1.2.3.7. After the finished
repair weld has reached ambient temperature, it shall be examined to
the requirements of para. 6.1.2.3.2., using the same nondestructive
examination technique that was used to examine the weld groove.
6.1.2.3.8. The vessel shall be
hydrostatically tested in accordance with PW-54.
6.1.2.3.9. The Manufacturer
shall obtain the approval of the Authorized Inspector, prior to making
the repair.

6.2. Repair Procedure For Minor Defects

6.2.3. Minor repairs need not be documented
6.2.4. The defects shall be removed by grinding or other suitable method
provided the following conditions are met:
a. The remaining wall thickness is not reduced less than the
minimum thickness required by the specification or drawing.

Second Edition
 DOCUMENT NO. :
Weld Repair W-QC-A-006
Control Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 9 of 10 1

b. The depression of the repaired portion after removal of defect

is blended smoothly into the adjacent surface.

7. EXHIBIT :

Exhibit 1 : NDE Tracing/Reader Sheet

Exhibit 1 : NDE Tracing/Reader Sheet

NDE TRACING/READER SHEET

PROJECTED NO : DATE RAISED :

Second Edition
 DOCUMENT NO. :
Weld Repair W-QC-A-006
Control Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 10 of 1
10

CUSTOMER : REF NO. :

JOB NO. : NDE REP. NO. :
ITEM TAG NO. : DATE START :
ITEM NAME : DATE FINISH :
I. NDE INSTRUCTION
The following weld joints to be examined WELDER ID
-
-
-
-
-
II. EXAMINATION RESULTS/FINDING & RECOMMENDATION
(Type/Size/Depth)

NOTE : If column is not enough than continuation sheets to add

DISTRIBUTION : Production Engineer, QC Engineer/Welding Engineer/Authorized
Inspector

Prepared by Verified by Closed Out Verification

NDE Level………. QC Engineer Reviewed/Witnessed Authorized Inspector

Date : Date : Date : Date :
W-QC-A-006.E1

Second Edition