Welding Repair Procedure

JG Summit Stage 1
A4-JGS1EP-EPC1-QP-014 Rev. B Page 1 of 12

Expansion Project

Welding Repair Procedure

PROJECT NAME : JG Summit Stage 1 Expansion Project

PROJECT NO. : A7LZ

OWNER : JG SUMMIT OLEFINS CORPORATION

CONTRACTOR : VENTANAS PHILIPPINES CONSTRUCTION INC.

SUBCONTRACTOR : AG&P

LOCATION : Barangay Simlong, Batangas City

: A4-JGS1EP-EPC1-QP-014
DOCUMENT NO.

4 - ACCEPTED WITH MINOR COMMENTS

B 30 Jan 18 Issued for Review MJ LEE SN KANG SW LEE
Revise per Purchaser comments and proceed with all
work defined by the data. Resubmit the revised data
for final acceptance.
A 21 Dec 18 Issued for Review MJ LEE SN KANG
Authorization to proceed does not relieve Contractor
SW LEE
/Supplier of its responsibility or liability under the
Contract and/or Purchase Order.

PREPARED CHECKED APPROVED

REV. DATE DESCRIPTION
BY BY BY
Project Document No.: A4-JGS1EP-EPC1-QP-014
 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

TABLE OF CONTENTS

1. Objective ...................................................................................................................... 4

2. Scope............................................................................................................................ 4

3. References ................................................................................................................... 4

4. Definitions .................................................................................................................... 5

5. Responsibilities ........................................................................................................... 5

6. Tools & Equipment ...................................................................................................... 5

7. Procedure ..................................................................................................................... 6

7.1 Repair of Defective Welds ..................................................................................... 6

7.2 Treated Arc Strikes ................................................................................................ 6

7.3 Removal of Temporary Attachment ....................................................................... 7

7.4 Surface Weld Bulit Up............................................................................................ 7

7.5 Restoration of Structural Steel Base Metal with Dislocated Holes… ...................... 7

7.6 Repair of Excessive Reinforcement ....................................................................... 8

7.7 Repair of Poor Appearance of Completed Weld .................................................... 9

7.8 Repair of Defective Weld Capping ......................................................................... 9

8. Notes ............................................................................................................................ 9

9. Appendices ................................................................................................................ 10

Appendix A (1/2) – Weld Repair Log Sheet.................................................................. 11

Appendix B (2/2) – Weld Repair Log Sheet.................................................................. 12

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

1. Objective

This procedure is established to provide guidelines in the repair of weld and base metal
defects for JG Summit Stage 1 Expansion Project package 1 (Naptha Cracking Expansion).

2. Scope

This procedure covers the appropriate methods of identification, repair and acceptance after
recertification of carbon, low alloy and high alloy steels for VPCI – Mechanical & Piping Steel
Structure Installation Work.

3. References

Codes, Standards, Legal And Other Regulations

Reference Title Description
ISO 9001:2015 Quality Management System - Requirements
Qualification Standard for Welding, Brazing, and
Fusing Procedures; Welders; Brazers; and Welding
ASME IX: 2017 Ed.
Brazing and Fusing Operators: QW-202.3 Weld
Repair and Build Up
ASME B31.3: 2016 Ed. Process Piping: Class 328.6 Weld Repair
American welding Society (AWS)
AWS D1.1; 2015 Ed. Structural Welding Code Steel latest edition including
addenda: Clause 5.25 Repair
American Institute of Steel Construction
AISC 201-06 Certification Program for Structural Steel Fabricators
Standard for Steel Building Structures—2006
Standard Specification for General Requirements for
ASTM A6-16a Rolled Structural Steel Bars, Plates, Shapes, and
sheet Piling: Clause 9.5 Repair by Welding

REFERENCED PROJECT SPECIFICATIONS, MANUALS, ETC.

Document No. Document Title
A4-JGS1EP-ES-50-010 Construction Work of Piping
A4-JGS1EP-ES-55-004 Welding and NDE for Pressure Retaining Components
A4-JGS1EP-EPC1-GS-80-
Welding Control Procedure
013
A4-JGS1EP-EPC1-GS-80-
Field Inspection & Test Procedure/Plan
009
A4-JGS1EP-EPC1-GS-81-
NDE Procedure
014

QMS Documents
Document No. Document Title
AGP-00000-P-L-13-
Repair of Weld and Base Metal Defects
0001.00

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

4. Definitions

MT - Magnetic Particle Testing

NCR – Non – Conformity Report

NDE – Non – Destructive Examination (PT/MT/UT/RT/VT)

PT - Liquid Penetrant Testing

PWHT – Post Weld Heat Treatment

RT – Radiographic Testing

SMAW – Shielded Metal Arc Welding

SS – Stainless Steel

UT – Ultrasonic Testing

VT – Visual Testing

WPS – Welding Procedure Specification

5. Responsibilities

Production Welding Supervisor – is responsible for assigning and instructing qualified

welders to perform repair welding in accordance with this work instruction with reference to
the applicable WPS

QC Inspector – is responsible in the preparation of NDT request as needed for every

repair welding to be performed, verification of intensity of defect based on NDE report
before repair, and re-inspection of affected area after the repair

NDE Technician – is responsible for all NDE needed in the repair works. NDE shall be
performed by personnel certified in accordance with ASNT recommended practice SNT-
TC-1A. NDE Level II or III shall be responsible for the interpretation of examination results

Project Manager – is responsible for the review and approval of the intended repairs by
welding (including applicable WPS), for welds and base metal

6. Tools & Equipment

 Apron
 Grinding Machine/Grinding Disc
 Heated Quiver
 Heating Torch or Electrical Resistance Heating Equipment
 Steel Brush ( for Carbon Steel material)
 Steel Brush ( for Stainless Steel material)
 TIG torch assembly with accessories
 Welding Gloves
 Welding Machine
 Welding Mask

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

7. Procedure

7.1 Repair of Defective Welds

7.1.1 Verify and identify the type, location and depth of defect from the finished NDE
performed.

7.1.2 Identify the material specifications of the base metal. Record the applicable
Code for any potential weld repair.

7.1.3 Defects shall be removed by mechanical means or by thermal gouging

processes. Remove defects by grinding or gouging to clean, sound metal.

7.1.4 Contour the excavation to provide groove geometry appropriate or deposition

of the required repair weld. Excavated groove shall be 50 mm long measured
at defect depth even if the defect itself is smaller; depth ratio shall be 2:1.

7.1.5 Perform Liquid Penetrant Examination (PT) in accordance with approved NDE
procedures on the affected area to confirm if the entire defect has been
completely removed after excavation.

7.1.6 Perform repair welding in accordance with the original WPS using qualified
welders or welding operators recognizing that the cavit to be repair welded will
differ in contour and dimensions from the normal joint preparation and may
present different restrain conditions. Welding parameters (e.g. heat input,
interpass temp.) are to be strictly followed from the reference WPS.

7.1.7 Conduct appropriate NDE to completed repair weld after finished repair weld
has reached ambient temperature and upon acceptance by visual examination.
Completed repair weld shall be inspected using the same non – destructive
examination that was used for the original weld.

7.1.8 Conduct again post weld heat treatment in all repair welding performed from a
post weld heat treated component according to its original PWHT conditions.

7.2 Treated Arc Strikes

7.2.1 Remove the arc strike by light grinding. The area around the arc strike shall be
ground to a smooth and shallow contour.

7.2.2 Grind the defects not greater than 10% of the base metal thickness or 0.8 mm
in depth, whichever is smaller, and in no case rupturing the minimum required
thickness.

7.2.3 Verify the defect removal by performing VT or PT (if required) on the affected
area.

7.2.4 Refer to item 7.4 in facilitating weld metal built up or buttering in cases of over
grinding.

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

7.3 Removal of Temporary Attachments

7.3.1 Remove temporary attachments by grinding or cutting with a flame torch on the
surface of the steel plate or pipe with no damage to the base material. This shall
be done progressively as the various items or portions of the structure are
completed. Gouging-out of attachments by arc-cutting below the plate surface
is not permitted.

7.3.2 Never remove the temporary attachments by breaking the back of the securing
fillet welds.

7.3.3 Flush grind remaining welds. Ground surface shall not be greater than 10% of
the base metal thickness or 0.8mm in depth, whichever is smaller and in no
case rupturing the minimum required thickness of the base material.

7.3.4 Verify the blended area by performing VT or PT.

7.3.5 Refer to item 7.4 in facilitating weld metal built up or buttering in cases of over
grinding.

7.4 Surface Weld Buildup

7.4.1 Ensure that the surface to be buildup is free from loose or thick scale, slag, rust,
moisture, grease and other foreign matters that would affect the quality of the
weld deposit.

7.4.2 Grind or brush all ragged and irregular edges or surfaces to clean and sound
metal.

7.4.3 Conduct PT (if required) to ensure that the affected surface is free from defects.

7.4.4 Conduct repair welding in accordance with approved WPS using qualified
welders or welding operators recognizing that the cavity to be repair welded will
differ in contour and dimensions from the normal joint preparation and may
present different restrain conditions. Welding parameters (e.g. heat input, inter
pass temp.) are to be strictly followed from the reference WPS. WPS qualified
on groove welds is also applicable for build-up.

7.4.5 Ground smooth the capping pass upon completion of weld and flush with the
required surface preparation.

7.4.6 Perform PT over the full surface of the deposit and check if discontinuities are
present. The finished surface shall be free from cracks, porosity, arc strikes,
spatter, lack of fusion and all other surface defects.

7.5 Restoration of Structural Steel Base Metals with Dislocated Holes

7.5.1 For all misdrilled holes, the location, thickness, material, size, proposed solution
and other details shall be submitted for approval. In some cases, the solution is
to leave the hole and not do a repair.

7.5.2 Ensure that the surfaces in which weld metal is to be deposited are smooth,
uniform, and free of fins, cracks, and discontinuities Paint and other foreign

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

materials shall be removed from both sides of the affected hole for at least 1
inch adjacent from its edge.

7.5.3 Ensure that the backing materials to be used are the same type or equivalent
to the base metal to be restored. Preheating on the base metal shall also be
performed if indicated in the WPS.

7.5.4 Perform plug welding on flat position when possible. Weld metal shall fill the
entire hole and no insert shall be used, if a new hole will be drilled within 50mm
of the weld repair.

7.5.5 Balance the applied heat to eliminate distortions.

7.5.6 Conduct MT after restoration or seal welding. PT shall be used for stainless
steel

7.5.7 For materials with ¼ inch (6.0mm) thickness and below:

 Place backing plate and tack weld at least four sides of the plate to the
structural member with dislocated holes to be restored.
 Conduct repair welding in accordance with an approved WPS using
qualified welders or welding operators. Starting from the hole edge, begin
welding traveling through a spiral path up to the hole center. Remove slag
and use pencil grinder after each pass or layer. Repeat welding until hole
is completely filled with deposited weld metal.
 Remove backing plate by grinding or gouging. Repeat welding until hole is
completely filled with deposited weld metal. Flush ground restored hole and
conduct MT to verify the repair welding performed.

7.5.8 For materials greater than ¼ inch (6.0mm) thickness:

 Insert steel backing material at one half the hole depth (1/2t) and tack weld
or seal weld to the structural member with dislocated holes to be restored.
 Gouge first side to form a “U” shape cavity and fill with weld metal following
same procedure on par. 7.5.7, Bullet 2.
 Gouge the other side after the first side has been welded to make another
“U” shape cavity completely removing the temporary backing material.
 Resume welding following same procedure on par. 7.5.7, Bullet 2.
 Flush grind both sides of restored hole and conduct MT to verify the repair
welding performed.

7.6 Repair of Excessive Reinforcement

7.6.1 Grind excessive reinforcement where deemed harmful or cause of interference

until the required height is achieved based on code and design requirements.

7.6.2 Blend into the adjacent base metal the edge of the reinforcement so as to avoid
sharp notches, crevices or corners.

7.6.3 Conduct VT on the blended area to verify effectiveness of repair welding

performed.

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

7.7 Repair of Poor Appearance of Completed Weld

7.7.1 Grind off the welding capping pass of the entire joint or appear with poor
appearance if localized. PT or MT the ground surface and grind out any
indications until PT/MT shows that the surface is defect free.

7.7.2 When the grinding has gone below the base metal, perform re-welding as
prescribed in the applicable WPS with emphasis on the correct welding
parameters such as amperage, voltage, travel speed and heat input intended
for the weld capping pass.

7.7.3 Conduct Visual Inspection and MT of the recap joint. Conduct additional NDE
specified on the original weld.

7.8 Repair of Defective Weld Capping Due to Out-Off Specification Test Result (i.e.
Hardness Testing, etc.)

7.8.1 Grind off the weld capping pass of the entire joint or the affected area from the
“FAILED” disposition of the particular test performed. Retest using the same
test method and criteria. If weld still fails, additional grinding will be required.

7.8.2 For heavy wall carbon steel and Cr-Mo material, cover the affected area or joint
with an insulating blanket after grinding or apply preheating as per approved
WPS so as to retard the cooling rate brought by the heat induced from grinding.

7.8.3 Perform re-welding as prescribed in the applicable WPS with emphasis on the
correct welding parameters such as amperage, voltage, travel speed and heat
input intended for the weld capping.

7.8.4 Conduct examination based from the previous method performed.

7.8.5 Repeat the previous testing performed on the weld capping pass and determine
the needed disposition after verifying the repair welding (did not cause any other
defects from the ones described above) through NDE.

7.9 Notes

7.9.1 Use appropriate tools for each type of material. In the case of high alloy steels
such as Stainless Steel, only iron free wire brushes, grinding discs, etc. shall be
used. This is to prevent further contamination on the part being repaired.

7.9.2 When presenting defects (not limited to cracks) intended for repair, it is then
imperative that a clear map be shown. Such map shall include the type of defect,
location, size and depth. The reference NDE report shall also be presented.

7.9.3 No rectification, repair or modification shall be made without the approval of the
Project Manager or customer when required. This holds essentially to repairs
which might affect the structural integrity of the affected part or component.

7.9.4 Second (2nd) repair attempt of a given defects requires written permission to
proceed with such repairs from the Purchaser and Owner prior proceeding.

7.9.5 All defective welds shall be recorded in the Weld Repair Log Sheet (Appendix
A). If applicable, two tracer shots shall be taken for every defective weld
detected

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

7.9.6 All NDE activities which will be put on record as needed in the repair welding
activity and shall be administered only by qualified NDE technicians.
Radiographs of repairs shall include an “R” in the radiograph identification.

7.9.7 For repair welding using SMAW, the low hydrogen type of electrode shall be
used. The electrode shall be properly conditioned in accordance with SFA 5.1,
SFA 5.5, or from the electrode manufacturer’s recommended conditions.

7.9.8 For repair welding of rejected welds welded by automatic welding process,
approved welding procedure specification using manual process may be used.

Automatic (Machine) WPS Applicable WPS for Repair

Document No WPS No. Process Material Document No. WPS No. Process
AGP‐18059‐WE‐X‐12‐0003.00 AG&P/As:17:004 GTAW + GTAW (Orbital) CS
AGP‐18059‐WE‐X‐12‐0021.00 AG&P/As:16:014R1 GTAW (Manual)
AGP‐18059‐WE‐X‐12‐0004.00 AG&P/As:16:014 GTAW (Machine) CS
AGP‐18059‐WE‐X‐12‐0006.00 AG&P/As:16:015 GTAW/SAW (Machine) CS Cut & re‐weld
AGP‐18059‐WE‐X‐12‐0018.00 AG&P/As:18:017 GTAW (Machine) LTCS AGP‐18059‐WE‐X‐12‐0012.00 AG&P/As:18:029 GTAW (Manual)
AGP‐18059‐WE‐X‐12‐0016.00 AG&P/As:18:010 GTAW (Machine) SS (Cryogenic) AGP‐18059‐WE‐X‐12‐0014.00 AG&P/As:18:031
GTAW (Manual)
AGP‐18059‐WE‐X‐12‐0019.00 AG&P/As:18:027 GTAW (Machine) SS (Cryogenic) AGP‐18059‐WE‐X‐12‐0013.00 AG&P/As:18:030
AGP‐18059‐WE‐X‐12‐0017.00 AG&P/As:18:016 GTAW (Machine) SS (Non‐Cryogenic) AGP‐18059‐WE‐X‐12‐0022.00 AG&P/As:18:016R1 GTAW (Manual)

7.9.9 All applicable WPS qualified on groove welds are applicable for weld repairs to
groove and fillet welds and for weld metal/base metal. Selection of the
applicable WPS shall be based on the type of material involved and the required
thickness of weld metal to be deposited.

7.9.10 Welding Repair of PWHT’d components without subsequent PWHT requires

Purchaser’s and Owner’s written permission.

7.9.11 VPCI shall be notified on all welds rejected on RT/UT and no welding repair to
be conducted without VPCI approval.

7.9.12 All procedures for repair welding on base materials shall be approved by the
Owner before making the repair.

8. Appendices

Appendix A (1/2) – Weld Repair Log Sheet

Appendix A (2/2) – Weld Repair Log Sheet

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

Appendix A

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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 Weld Repair Procedure for JG Summit Stage1 Expansion
Project Package 1 (Naphtha Cracking Expansion)
Project Document No.: A4-JGS1EP-EPC1-QP-014

Appendix B

Batangas Heavy Fabrication, Yard 1, San Roque, Bauan, Batangas 4201, Philippines
Phone: +63 (43) 740 5800 l www.agp.ph

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