SGS PAKISTAN LIMITED

WELDING REPAIRING PROCEDURE FOR

TUBING & CASING
FOR
UNITED ENERGY PAKISTAN LIMITED

Document No: Rev. No: Issue Date:

SGS-UEP-TUBE-001 00 26/07/2018

Prepared & Checked By Approved By

ALI DAD KHAN

SGS PAKISTAN UEP Pakistan

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CONTENTS

1. SCOPE

2. REFERENCE

3. GENERAL INSTRUCTION

4. REPAIR IN BUTT WELDS

5. REPAIR IN FILLET WELDS

6. MONITORING AND RECORD

1. SCOPE:

This procedure covers the requirements for repairing all nonconformities in welded joints, which
is limited to material API 5CT Gr-2, to API 5CT Gr-2 and API 5CT Gr-2 to P1 Gr-1.

2. REFERENCE:

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2.1 ASME Sec. IX (Welding, Brazing and Fusing Qualification)

2.2 API 582 (Welding Guidelines for the Chemical, Oil, and Gas Industries)
2.3 API 577 (Welding Inspection and Metallurgy)
2.4 API 5CT (Specification for Casing & Tubing)
2.5 API 5L (Specification of Line Pipe)
2.6 NACE MR0175/ ISO 15156-1
2.7 ASME Sec II Part A
2.8 WPS-UEP-Tube-006
2.9 WPS UEP-Tube-007

3. GENERAL INSTRUCTIONS:

3.1 All rejected welds, as a result of visual and non-destructive examination shall be
identified by QA/QC personnel.
3.2 Any defect ascertained by the examinations and judged unacceptable, shall be
removed according to this procedure.
3.3 Two (02) repair attempts shall be allowed on anyone defective area.
3.4 Thermal cutting is not permitted at any case.
3.5 Welder must be qualified as per assigned approved WPS.
3.6 Weld Face and their adjacent area up to 4” either side shall be free of all type of
contaminants such as moisture, oil, dust, rust and grease.
3.7 Inspection and monitoring devices must be calibrated by any TPI.

4. REPAIR IN BUTT WELDS:

Any butt weld which is judge by unacceptable by visual inspection or non-destructive

examination, shall be rectified as under,

4.1 SURFACE REPAIR

Surface imperfections such as porosity, under cut, excess reinforcement, lack of side wall fusion,
inclusion and under fill shall be rectified in accordance following procedure,

- Welded joint shall be identified and mark the location by QA/QC inspector.
- Defects in weld metal shall be completely removed by grinding or other mechanical means
except thermal process.
- After defect removal, DPT shall be carried out to ensure that defect has been removed.
- Weld face/groove and base metal shall be cleaned by cleaner, in order to remove all sulphur
and chlorine contents.
- Pre-heat weld face/groove and base metal where welding shall be done at least 4” either
sides at the temperature mentioned in approved WPS. Preheat temperature shall be
maintained till completion of weld repair.

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- Make sure pre-heat temperature rise at the temperature require as per WPS,
then welding shall be carried out by qualified welder.
- Continues monitoring is required by welding inspector during and after welding in order to
satisfy that all essential and non-essential variable being followed as per approved WPS.
- After completion weld repair, visual inspection was carried out and followed by appropriate
NDE to satisfy the integrity of weld and its HAZ area.

Note: In any case, crack is present in base metal then defective base metal shall be
removed least 4” both side of crack edge.

4.2 CUT AND REWELD

If the welded joint required repair by cut and reweld then following exercise shall be carried out.

- Mark and highlighted defective weld by QA/QC personal.

- Cut the joint form weld center by grinder or other mechanical means except thermal cutting.
- Grind out carefully in order to remove cutting surface, defects and weld remnant.
- Hardness testing shall be carried out on weld face and adjacent areas. Hardness shall not
exceed 241 HB.
- Make bevel ends of adjoining surfaces and perform DPT internal & external sides up to 1”
from the edge of bevel, to ensure adjoining surfaces are free of surface defects.
- Fit up shall be done and ensure all prerequisite of welding have been done such as purge
arrangement and etc.
- Pre-heat weld joint and base metal where welding shall be done at least 4” either sides at the
temperature mentioned in approved WPS. Preheat shall be maintained till completion of
weld.
- Make sure pre-heat temperature rise at the temperature require as per WPS, then welding
shall be carried out by qualified welder.
- Continues monitoring is required by welding inspector during and after welding in order to
satisfy that all essential and non-essential variable being followed as per approved WPS.
- After completion weld, visual inspection was carried out and followed by appropriate NDE
to satisfy the integrity of weld and its HAZ area.

Note: In any case, hardness is increased 241 HB, then defective portion shall be
replaced with pup piece. Minimum pup piece length as per UEPL specification.

5. REPAIR IN FILLET WELDS

Any fillet weld which is judge by unacceptable by visual inspection or non-destructive

examination, shall be rectified as under,

5.1 SURFACE REPAIR IN FILLET JOINT

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Surface imperfections such as porosity, under cut, excess reinforcement,
inclusion and under fill shall be rectified in accordance following procedure,

- Welded joint shall be identified and mark the location by QA/QC inspector.
- Defects in weld metal shall be completely removed by grinding or other mechanical means.
- After defect removal, DPT shall be carried out to ensure that defect has been removed.
- Weld face/groove and base metal shall be cleaned by cleaner, in order to remove all sulphur
and chlorine contents.
- Pre-heat weld face/groove and base metal where welding shall be done at least 4” either
sides at the temperature mentioned in approved WPS. Preheat temperature shall be
maintained till completion of weld.
- Make sure pre-heat temperature rise at the temperature require as per WPS, then welding
shall be carried out by qualified welder.
- Continues monitoring is required by welding inspector during and after welding in order to
satisfy that all essential and non-essential variable being followed as per approved WPS.
- After completion fillet weld repair, visual inspection was carried out and followed by
appropriate NDE to satisfy the integrity of weld and its HAZ area.

Note: In any case, crack is present in base metal then defective base metal shall be
removed least 4” both side of crack edge.

5.2 REWELD FILLET JOINT

If any fillet weld required repair by complete reweld then following exercise shall be carried out.

- Mark and highlighted defective weld by QA/QC personal.

- Grind out carefully in order to remove defective weld deposition.
- Hardness testing shall be carried out on base metal where welding shall be performed. Hardness
shall not exceed 241 HB.
- DPT shall be performed on adjoining surfaces in order to ensure adjoining surfaces are free of
surface defects.
- Pre-heat weld location and base metal where welding shall be done at least 4” either sides at the
temperature mentioned in approved WPS. Preheat shall be maintained till completion of
weld.
- Make sure pre-heat temperature rise at the temperature require as per WPS, then welding shall be
carried out by qualified welder.
- Continues monitoring is required by welding inspector during and after welding in order to
satisfy that all essential and non-essential variable being followed as per approved WPS.
- After completion weld, visual inspection was carried out and followed by appropriate NDE to
satisfy the integrity of weld and its HAZ area.

Note:
1) In any case, hardness is increased 241 HB, then defective portion shall be
replaced with pup piece. Minimum pup piece length as per UEPL specification.

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2) In any case, crack is present in base metal then defective base

metal shall be removed least 4” both side of crack edge.

6. MONITORING AND RECORD

Results of the weld inspection should be completely and accurately documented. The inspection
report, in many cases will become a permanent record to be maintained and referenced for the life
of the weld or part being inspected.

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