CONTRACTOR Melut Basin Oil Development Project, OWNER PMC
Contract No.: DPOC/23/20-4930N
EPCC for Field Surface Facilities & Power
Distribution System for Well Tie-in in Blocks 3 & 7
WELDING REPAIR INSPECTION
PROCEDURE
Document No. : DPOC-4930N-PR-QAC-008 Rev. 0 Date: 12-09-2023 Page.: 1/5
DAR PETROLEUM OPERATING COMPANY
ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING
FOR FIELD SURFACE FACILITIES AND POWER DISTRIBUTION SYSTEM
FOR WELL TIE-IN IN BLOCKS 3 & 7
Document Title:
WELDING REPAIR INSPECTION PROCEDURE
Doc ument No.: DPOC-4930N-PR-QAC-008
CONTRACT NO.: – DPOC/23/20-4930N
16/09/20
6 3 16/09/2023
23
Issued for
0 Approval
12.09.2023 Waseem Jimmy T. Mr. Hazar
Issued for
A Review
07.09.2023 Waseem Jimmy T. Mr. Hazar
PMC/
Rev. Description Date Prepared By Checked By Approved By
DPOC
CONTRACTOR Melut Basin Oil Development Project, OWNER PMC
Contract No.: DPOC/23/20-4930N
EPCC for Field Surface Facilities & Power
Distribution System for Well Tie-in in Blocks 3 & 7
WELDING REPAIR INSPECTION
PROCEDURE
Document No. : DPOC-4930N-PR-QAC-008 Rev. 0 Date: 12-09-2023 Page.: 2/5
TABLE OF CONTENTS
1.0 SCOPE Page-03
2.0 SPECIFICATIONS Page-03
3.0 OBJECTIVE Page-03
4.0 RESPONSIBILITY Page-03
5.0 REPAIRS OF BASE MATERIALS Page-04
6.0 WELDING REPAIRS Page-04
7.0 EXAMINATION OF REPAIRED WELDS Page-05
8.0 WELD REPAIR RECORD Page-05
9.0 REVISION NOTE Page-05
CONTRACTOR Melut Basin Oil Development Project, OWNER PMC
Contract No.: DPOC/23/20-4930N
EPCC for Field Surface Facilities & Power
Distribution System for Well Tie-in in Blocks 3 & 7
WELDING REPAIR INSPECTION
PROCEDURE
Document No. : DPOC-4930N-PR-QAC-008 Rev. 0 Date: 12-09-2023 Page.: 3/5
1.0 SCOPE
This procedure describes the requirements for weld repair as per contract specifications,
codes and standards applicable to the Field Production Facilities and Field Surface
Facilities Project. This procedure covers the repair of defects in plate materials, fittings,
and welds.
2.0 SPECIFICATIONS
Specification:
DPOC-SP-CIV-015 : Specification for Structure Steel Pre-fabrication and Erection
DPOC-SP-MEC-011 : Specification for Equipment Welding
DPOC-SP-MEC-020 : Specification for Welded Pressure Vessels
DPOC-SP-PIP-005 : Specification for Pipe Welding
DPOC-SP-PIP-004 : Specification for Piping fabrication
Codes:
ASME Section IX : Welding & Brazing Qualifications
ASME 31.3 : Code for Pressure Piping,
AWS-D1.1 : Structural Steel Welding Code
API 650 : Welded for Steel Tank for Oil Storage
3.0 OBJECTIVE
The objective of this procedure is to ensure that defects are correctly removed and the
repairs are adequately performed. All weld repairs are controlled by this procedure.
4.0 RESPONSIBILITY
4.1 QC welding engineer shall be responsible for the following:
Confirm weld defects to be repaired.
Verifying that X-ray technicians locate and layout the area to be repaired using the
lead marker tape originally used.
Inform the welder regarding type and probable depth of defects.
Resolve problems raised during weld repair.
Supervise all phases of work during weld repairs, ensure that repair activities
are performed in accordance with the approved repair welding procedure
specifications.
4.2 QC welding inspector shall be responsible for the following:
• Identify and mark welding seam defects on the weldment.
• Check the preparation and clean-up of groove.
• Record the weld inspection
• Verify that welding parameters & consumables adopted by welders conform to the
requirements of welding procedure specification (WPS).
CONTRACTOR Melut Basin Oil Development Project, OWNER PMC
Contract No.: DPOC/23/20-4930N
EPCC for Field Surface Facilities & Power
Distribution System for Well Tie-in in Blocks 3 & 7
WELDING REPAIR INSPECTION
PROCEDURE
Document No. : DPOC-4930N-PR-QAC-008 Rev. 0 Date: 12-09-2023 Page.: 4/5
5.0 REPAIRS OF BASE MATERIALS
5.1 Imperfections or damage to pipe materials or fittings may be removed by grinding
provided that the wall thickness is not below the minimum. Requirement specified in
application code. Thickness check shall be performed after final grinding is completed.
When minimum, wall thickness is not maintained, requirements of Section 6.0
“WELDING REPAIRS” shall be applied for tanks and structural steel only. Gouges
below corrosion allowance on pipeline and piping shall be cut out. Local grinding of
flange faces machined or seating surfaces shall not be permitted.
5.2 The ground area shall be carefully dressed to ensure a smooth transition with the parent
metal.
5.3 For piping, the ground area shall be inspected by Liquid Penetrant Examination to ensure
that the defects have been removed.
6.0 WELDING REPAIRS
6.1 The defects that cannot be removed by surface grinding shall be ground out until
completely removed before welding.
6.2 Weld repair shall be carried out using the approved WPS. The radiographs marked R for
“Repair” are to be reviewed indicating the Radiograph Reference No., line No., diameter,
and thickness. The reference location (identified by lead-markers on radiograph) and the
type of defect are to be marked on the pipe by the X-ray technician.
6.3 As butt-welds on pipes are single ‘V’ butts, the location of a defect on radiographs is
traced back on pipe weld profile. The instruction “grind from the outside” will be issued
and the type of defect is written in most cases by QC welding engineer. Repair welding of
defects in welds or base materials shall not be performed from inside.
6.4 For the groove weld or double V groove weld on plates, the locations of a defect on
radiographs are traced back on the plate weld profile. On tank weld repairs, the location to
be ground is determined whether it is close to inside or outside the tank. Defects shall be
ground from the side closest to the defects.
6.5 Welds containing cracks shall be subjected to additional non-destructive examination
(Magnetic Particle) and cracks shall be cut out for piping & pipeline, then the repair will
be decided by the welding QC engineer and the OWNER’s inspector. Based on
CONTRACT requirements, repair welding will only be permitted after consideration of
the nature and cause of cracking.
6.6 The excavated area shall be examined by liquid Penetration technique to ensure complete
removal of the defects before repair welding.
6.7 For repair of carbon steel welds, grinding, chipping etc. without any need of pre-heating
is permitted. For piping, if pre-heating is required, the applied pre-heat shall be 50C
higher than that of the welding procedure specification for carbon-manganese steel and
low alloy steels.
6.8 Weld repair of austenite stainless steel (thickness low 18mm) does not require pre-heat or
post-weld heat treatment, except for specialized requirements.
6.9 Qualified welders using approved Welding Procedure Specification (WPS), shall carry
CONTRACTOR Melut Basin Oil Development Project, OWNER PMC
Contract No.: DPOC/23/20-4930N
EPCC for Field Surface Facilities & Power
Distribution System for Well Tie-in in Blocks 3 & 7
WELDING REPAIR INSPECTION
PROCEDURE
Document No. : DPOC-4930N-PR-QAC-008 Rev. 0 Date: 12-09-2023 Page.: 5/5
out all repair the work.
6.10 The excavated area shall be sufficiently deep & long to remove the defect.
6.11 Repair welding shall be conducted prior to any post-weld heat treatment or hydrostatic
test. If any repair is required after post-weld heat treatment or hydrostatic test, the
repaired weld shall be PWHT or hydrostatically tested, as applicable.
6.12 In the event that the OWNER does not authorize a major weld repair, the weld shall be
cut out and the joint weld shall be re-welded. The new weld shall have the same weld
identification number with suffix “RW” indicating a “cut out and reweld” weld. For
pipeline, if there are 3 or more defect found, the weld shall be cut out. No more than 1
repair is allowed in any 6” of weld metal, otherwise the weld shall be cut out.
6.13 When the ground area of the base metal is welded to restore the minimum wall thickness,
the welded area shall be dressed to a smooth transition and assure that the repaired area
meets the minimum wall thickness requirements. All repair welds shall be examined as
required in weld examination procedure.
7.0 EXAMINATION OF REPAIRED WELDS
Examination of repaired welds shall be done by the same examination method that
originally discovered the defect. An additional examination method may also be used to
verify completion of repair. All the welds repaired shall be re-inspected according to
the welding inspection procedure (DPOC-4930N-PR-QAC-003).
8.0 WELD REPAIR RECORD
8.1 Status of all welding and weld repairs shall be maintained by the welding QC engineer.
8.2 Once it has been determined that there is a weld repair, the weld identification number
will be modified with a suffix R. For pipeline, only R1 is allowed.
8.3 All inspection and non-destructive examination reports of welds repaired shall be
reflected in the modified weld number.
9.0 REVISION NOTE
This procedure shall be revised if it is found to be inadequate for purposed work upon
completion of engineering/new construction practice/new site information or as requested
by OWNER.
