WHY REPAIR WELDING IS

CARRIED OUT
a.

b.

c.

If there is an unacceptable defect

existing in the weld region of the
component in service.
If there is an imperfection in the
base material which when left in
its place may impair the normal
function of the component.
Leads to failure if unattended.

REPAIR WELDING
1.

Base material repair welding

2.

Weld repair
a) SPOT Repair
b) Replacement of Joint (CUT & WELD)
- With addition of Spool Piece
- Without addition of Spool Piece

BASIC REQUIREMENTS OF
REPAIR WELDING
Better quality
Requires

than the original weld.

more care than original weld.

(Since it may introduce more defects
during repair)

PROBLEMS ASSOCIATED
WITH REPAIR WELDING
Incomplete

removal of defect.
Introduction of new defect due to improper
procedure, consumables, techniques.
Microstructure, material or toughness degradation
consumable, base material, HAZ crack. (Process
Heat input)
Residual stress and distortion.
Unfavorable environmental conditions that are
beyond control of welder, eg. Poor accessibility,
position, wind, rain, fit-up conditions.

 Select

Process
Welder
Consumable
Preheating arrangements
Equipments
Carryout

weld repair
Conduct NDT & Certify
Record the above activities

APPROACH TO WELD
REPAIR
I.

Establishing the cause of the initial

weld defect:Before attempting for a weld
repair, know the cause and type of the
weld defect already available, process
and welder to be employed and other
details related to the defect

II. Selection of welder

Use

only IBR qualified welder for Pr part

weld repair.
Check
Validity
Material qualified
Position
Thickness qualified
Diameter
Process
Job configuration
Genuinity of the certificate

 Apart

from verification of the certificate we

can arrange for a mock up test for the
welder & ascertain the suitability of the
welder.

III. Avoid welding wherever possible:Do not attempt any welding if it is

possible to avoid by resorting to dressing
technique for defects like undercuts,
notches which could be ground without
affecting the performance of the
components.

IV. Ensure the correct location of defect:To remove the defect positively
and properly, ensure the detection of the
location of the defect by using proper
NDE method and mark it correctly.

V. Make clean and smooth

surface for welding:Excavate a smooth and clean well
shaped cavity for better accessibility by
employing air arc gouging, grinding or
machining.

VI. Ensure complete removal of defect:After the removal of defect by

the above method ensure complete
removal by again conducting an
NDE.

VII. Avoid new defects:Avoid introducing new defects by

taking extreme care and precautions
while welding by employing proper and
skilled welder, good fit-up, good welding
conditions, techniques, consumables etc.
Use preferably flat position welding
wherever possible.

VIII. Micro-structure, material or toughness

degradation:There is possibility of degradation
of the material in micro-structure or
mechanical
properties
(Strength,
Toughness) by employing improper filler
wire, HAZ crack, process (Increase in
heat input) etc.

IX. Residual Stresses and Distortion:Due to additional welding and heat

input, the residual stress may be
increased, which may result in distortion.

X. Unfavorable Environmental condition:The conditions available for repair

welding may be unfavorable viz. Poor
accessibility, Awkward position, wind,
rain, poor fit-up conditions etc.

XI. Control the heat input:Precise control of heat input

during welding viz. Preheat, Postheat,
during welding and stress relieving after
welding will control the distortion of the
components.

XII. Final NDE:Perform final NDE and evaluate.

Ensure that the repair welding carried out
is sound and defect free.

ECONOMICS OF WELD
REPAIR
Direct

cost of repair welding (Welder,

Consumables etc.).
Additional cost of grinding, gauging,
NDE, Supervision, Time, Repetition
of repairs.
Interruption of work schedule and the
cost involved.

Generally it is estimated that

the cost of repair comes to
approx. to 2 to 3.5 times the
original welding cost for
repairing defect in a thick joint

Conclusion
IBR

clearance for Pr Part welding repair

Carryout NDT in the defective area
Ascertain the nature & location of the defect
Remove the defect
Conduct NDT & ensure the original defect is
completely removed