Document History
Issue Status &
Description

Issued for Review/Approval
Document Ref.
Rev
Issue Date
Prepared by
Contractor
2200016407-D5
-AWP -041GENMEC-PR-424
A
23-07-2023
K.Askary
2200016407-D5
-AWP -041GENMEC-PR-424
B
31-08-2023
K.Askary
2ND PAGE

Issued for use
Reviewed by
Supervising
Consultant
Approved by
Project
Manager
LIST OF CONTENTS
Contents
1.
PURPOSE ................................................................................................................................... 4
2.
SCOPE ........................................................................................................................................ 4
3.
DEFINITIONS, TERMS, AND ABBREVIATIONS........................................................................... 4
4.
REFERENCES .............................................................................................................................. 5
5.
RESPONSIBILITES .......................................................................................................................5
6.
REPAIR PROCEDURE ..................................................................................................................6
7.
SAFETY AND HEALTH .................................................................................................................8
8.
ATTACHMENT......................................................................................................................... .11
Procedure
Weld Repair Procedure for Carbon Steel
Pipeline & Fittings -Dammam 5
Doc. no
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1- Purpose:
The purpose of this document is to repair defects, fast and professional procedures for the
repair defects of CS carbon steel pipes in Field joints fabrication & insulation to comply with
designated standards and Project specifications in accordance with accepted codes of
practice.
It is written in such a way that it covers the vast majority of welding situations envisaged.
This method statement or process specification provides the minimum requirements that
govern the Shielded Metal Arc Welding (SMAW) of carbon steel pipes with grades. Design
procedural and quality assurance requirements are given. All work instructions and Weld
Procedure Specifications (WPS) used during welding shall satisfy the requirements of this
process specification. This documentation also gives the requirements for preparing,
qualifying and use of the Procedure Qualification Records (PQR).
2- Scope of Work
This procedure may be used for the repair of minor defects in weld such as Porosity,
undercut, crater, slag inclusion and major defect such as incomplete penetration,
incomplete fusion, and cracks; and other imperfection detected during fabrication & NDE
for Carbon steel pipes ASTM A53 Gr B. In this case no separate NCR is to be issued.
This procedure covers unacceptable defects by visual examination or non-destructive
examination
3- Definition and abbreviation
3.1
Definition
Client
NWC
Consultant
ILF
Contractor
ALKHORAYEF
Third party
Any third party has approved from NWC (TUV Sud).
3.2
Abbreviation
WPS
Welding Procedure Specification
PQR
Procedure Qualification Records
WPQ
Welding Procedure Qualification
METHOD STATEMENT
REPAIR PROCEDURE CS PIPES
NDT
Non-Destructive Testing
UT
Ultrasonic Testing
WPR
Welder performance Qualification Record
Shall
A provision that is binding (mandatory)
Should
A provision that is optional (non-mandatory)
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4- Reference
4.1
Design Drawing
4.2
Shop Drawing
4.3
Project Applicable Codes and Standards

API 1104
Standard for Welding Pipeline

ASME Section V
Non-Destructive Testing (NDT) Examination

ASME Section IX
Welding and Brazing Qualifications

AWWA C206-17
Standard for field welding of steel water pipe

TUVSUD/NDT/PAUT/API
Phased Arrays Ultrasonic Examination Procedure

TUV-SUD/NDT/MT/001
Magnetic Particle Examination Procedure

WPS No. -WA-WPS-004
5- Responsibilities
5.1
Sub-Contractor Responsibilities
5.1.1 Open the defect to reach to according to NDT marking
5.1.2 Have the testing third party record and certify the test results
5.1.3 All welding procedures to be used in this project shall be submitted on these
forms include:

Welding Procedure Specification (WPS)
5.2
Within WAFA AL AMAL Est. For Contracting, ultimate responsibility for all repair and
re-welding & insulation activities normally lies with the various main contractor.
5.3
Every site, of whatever size, is run as a separate entity with an individual designated
as being responsible to the main contractor concerned for that particular site.
METHOD STATEMENT
REPAIR PROCEDURE CS PIPES
5.4
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The main duties of the key site personnel are as follows:
a. Duties of the Welding Supervisor
The following highlight the primary duties of the Field Welding Supervisor:
5.5

Monitor that Safety and Environmental requirements, welding related
equipment, consumables, and tools according to site welding requirements.

Assure that all field welding is done in accordance with the current revision
of the Welding Procedure specification and relevant Codes.

Directing those operations associated with weldments in accordance with
the appropriate contract documents and codes to produce a satisfactory
product.

Assure that all field welding is done in accordance with the current
revision of the MOS, Welding Procedure specification and relevant Codes.

Identify any need for welder upgrading or training, and when required.
QC Inspector
•
•
•
•
•
•
Implementing inspection and test plans and procedures submitted by subcontractors
Witnessing NDT and welding inspection at workshop and site.
Coordinating witness test and inspection.
Reviewing and updating test and inspection reports and QC data issued by
subcontractors, and issuing them to QC Engineer.
Monitoring periodically if the calibration of testing equipment and tool are updated and
identifying any issues.
They are involved in all phases of the production lifecycle from evaluating raw materials
to inspecting finished products to verify they meet target specifications.
5.6 QA/QC Engineer
•
•
•
•
•
Ensuring that the products and services provided by a company meet the required
standards
Analysing inspection results receiving from QC Inspector
Meeting with clients to define pipeline requirements
Developing a method statement for the particular work on the site. He will make sure
that it is submitted to the Consultant or Engineer and should be approved prior to
starting the job on the site.
Issuing an internal non-conformance report and site observation to the subcontractors
and site construction team.
METHOD STATEMENT
REPAIR PROCEDURE CS PIPES
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6 Repair Procedure
6.1 General
All welding procedure specifications and welding procedure qualification records shall
conform to the requirement of the standard and the applicable codes. The weldment shall
prove that a weldment will provide the desired properties for construction. Where no
qualification code is applicable, the authorized persons of the consultant ILF/ Company
ALKHORAYEF shall decide.
6.1.1 When weld defects such as Porosity, Slag, cracks, pinholes and incomplete fusion
detected Visually during Installation or fabrication or by leakage tests or by the
examinations required by (QCP/ITP) and found to be reject able, it shall be removed by
mechanical means or by thermal grooving processes, it shall be removed by mechanical
means only (Grinding or Grinder who is clean the surface and open defect), after which
the joint shall be re-welded and re-examined.
6.1.2 Marking of any defect of joints shall be by TPL inspector or NDT level II working at
site according to NDE report.
6.1.3 When weld metal is added to make the repair, one of NDT methods required on the
original weld shall also, be used to inspect the repair weld. NDT of a repair weld
shall include, at a minimum, the total repair area plus 2 in. (50 mm) on each side of
the repair area. Repairs shall be considered acceptable when the repair area meets
the standards of acceptability of Section 9 or the acceptance criteria specified API
1104.
Visual testing shall be considered adequate visual means and repaired by grinding
without the addition of weld metal.
6.1.4 The repair work shall be performed using the original approved relevant project
WPS, assigned to the weld by the Welding Summary, unless welding joint that
originally made with SMAW weld repair to be done in accordance with approved
SMAW procedures.
6.1.5 For SMAW procedure the size of the welding electrodes shall be used according to
Approved WPS, MOS and Project requirements.
6.1.6 The repair area shall be preheated (IF NEEDED) to a minimum temperature as
specified in the original approved WPS.
6.1.7 The removal of unacceptable portion of weld shall be done by arc gouging and or
mechanical means such as chipping and grinding (Grinding or Grinder who is clean
the surface and open defect) without substantial removal of the base metal.
METHOD STATEMENT
REPAIR PROCEDURE CS PIPES
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6.1.8 For arc gouging the minimum preheat of the original WPS shall be used especially
when the defect is proved to crack, preheat shall be considered inside as outside,
more than 5 mm by and each end of the crack shall be removed.
6.1.9 Before welding the defects area, which removed by accepted method; the groove
shall be examined to verify defect removal using either the magnetic particles or
the liquid penetrant examination method.
6.1.10 If during initial examination 10% of any weld are rejected, additional 20% of the
same day production weld for the same welder or welding operators Shall be
examination. If this reveals additional detects then the remainder of the welder day
production shall be examination 100%.
6.1.11 The MT & PT shall be performed by using relevant PT & MT procedure and
performed by qualified personal, for reporting see Para 5.
6.1.12 The depth 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.
a)
The rework welding shall be performed using approved WPS qualified
6.1.13 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 affected zones.
6.1.14 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.
6.1.15 The maximum heat input (If applicable) for each weld layer not exceeds that used
in the procedure qualification test.
6.1.16 The maximum deposited weld bead width for any electrode shall be four times the
electrode core diameter.
6.1.17 The repair weld method shall be limited to the half bead weld repair technique as
follows:
a) The initial layer of weld metal shall be deposited over the entire area using
1/8 in (3mm) maximum diameter electrodes.
b) Approximately one half the thickness of this layer shall then be removed by
grinding (Grinding or Grinder who is clean the surface and open defect)
before depositing sub sequent layers.
METHOD STATEMENT
REPAIR PROCEDURE CS PIPES
Doc. no Wafa-MST-DOC-03
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c) The subsequent weld layers shall be deposited using 5/32 in.(4mm)
diameter electrodes, in such a manner as to assure tempering of the prior
6.1.18 Any final temper bead reinforcement shall be removed substantially flush with the
surface of the base material.
6.1.19 After the finished repair weld has reached ambient temperature, it shall be
examined using the same non-destructive examination technique that was used to
examine the weld groove.
6.1.20 Ensure that the defective area has a weld preparation to the relevant WPS And then
re-welding
- The bottom of the groove shall exceed the weld defect in length at least 10mm on
both sides.
- The width of the groove at the bottom shall be 4mm as minimum.
- The opening in cross section shall be 50º as minimum (see sketch).
- The slopes at the beginning and end of the groove shall be not exceeds 2:1 (see
sketch).
- The maximum thickness of layer 4mm.
7 Safety and Health
7.1.1 Specific Safety Precautions
1. Welders should not interfere or tamper with welding equipment.
2. Welders must wear protective clothing and eye protection when
welding or chipping slag from welds.
3. Any combustible material should be removed from the vicinity of
welding operations; where removal is not possible the material should
be protected.
METHOD STATEMENT
REPAIR PROCEDURE CS PIPES
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4. The area around the welding operation should be cordoned off to
protect other people from welding sparks or spatter.
5. In case of electric shock insulate welder from work place and ground
using dry insulation.
6. Wear dry gloves in addition to other safety wears.
7. Do not touch electrically hot parts or electrode with bare skin or wet
clothing.
8. Keep electrode holder and cable insulation in good condition.
7.1.2 Welding weather condition
The welding of SMAW shall not be done on draft or wend unless the weld is
protected by a shelter. Such shelter shall be of material.
Welding shall not be done in the following ambient condition;
1. When ambient temperature is lower than 20Co.
2. grease or oil on the surface
3. When surfaces are wet or exposed to rain.
4. When welding personnel exposed to inclement conditions.
7.1.3 Welding Process
1. The mains supply to the welding plant should be transformed down to a
safe working voltage (usually between 80 and 110 volts).
2. The actual welding circuit should be isolated from the mains.
3. Trailing leads should be as short as possible, armored, and visible to
avoid trip hazards or damage.
4. All equipment should be properly earthed.
5. All connections should be made with proper fittings or equipment.
6. Connection to the work to be welded should be made with cranes or
lugs.
7. When not in use, all welding equipment should be disconnected from
the mains supply, or isolated, and protected if left unattended for any
length of time.
8. Particular care must be exercised in damp weather to avoid contact with
the welding electrode or holder.
METHOD STATEMENT
REPAIR PROCEDURE CS PIPES
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9. Electrode stubs should be ejected into a metal container or other noncombustible receptacle.
7.1.4
Cutting Grinding (Grinding or Grinder who is clean the surface and open defect)
1. Always do an inspection on equipment before use to avoid injuries.
2. Grinder to be with dead man switch and without any locking
arrangement.
3. Wear the correct PPE for the grinding/cutting operation.
-
Eye protection (Glasses & face shield)
coverall
Apron
Gloves
Helmet
Safety goggles
Safety boots
Face shield for welding
Face shield for grinding
Reflective safety vest
4. Take the grinder with both hands and hold it firmly before start of the
operation.
5. When the grinder is switched off, hold it in your hands until the disk has
stopped turning.
6. Keep the grinder away from the body parts and avoid any loose clothing
near any rotating parts of the grinder.
7. Make sure that the sparks do not fly in the direction of other workers.
8. Do not drop the grinder or any other object onto the grinding (Grinding
or Grinder who is clean the surface and open defect) wheel as it may
crack the wheel.
9. Place all the off cut material in a container to avoid any injuries or
tripping hazards.
10. If the grinder is not in use, disconnect it from the power source and put
in safe place for storage or take back to the store.
METHOD STATEMENT
REPAIR PROCEDURE CS PIPES
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7.1.5 Pre-heating / Flame cutting
1. Remove combustibles & flammables from work area.
2. Check all cords are in good condition.
3. Wear required PPE’s. (Hand gloves, safety glasses, Face shield, Helmet,
safety shoes, masks)
7.1.6 Carry out Radiography OR PAUT of welding joints (IF REQUIRED)
1. Take necessary Radiography permit.
2. The authorized person conducting radiography must be approved by the
Supreme Council.
3. The person should be possessing dosimeter all the time.
4. Area to be barricaded indicating the radiation symbol from all the sides.
5. No un-authorized person should be allowed to enter the working area.
6. The barricading must be done up to the area where the radiation shows
on the meter is 25 m rem/ hr using calibrated instrument.
8 Attachment
1. Standard Forms
APPENDIX A
STANDARD FORMS
Title
Work Inspection Request WIR (General)
Visual Inspection Report Form
Reference
Rev.
Pages
PMF-012-QUA-013_02
0
1
0
1
AWPT-RE-CQC-005
NWC WATER IMPROVEMENT PROJECTS
DAMMAM-5 PROJECT
VISUAL INSPECTION REPORT
AWPT-RE-CQC-005 Rev.0
* ALL DIMENSIONAL INSPECTION CARRIED OUT ACCORDING TO
REPORT NO. :
CLIENT :
SURFACE CONDITION :
THE DRAWING SPECIFICATION..
CASTED
JOB No. :
* ALL N.D.T CARRIED OUT ACCORDING TO THE QUALITY
CONTROL PLAN
GROUND
AS WELDED
SYSTEM. No.:
*
MACHINED
LINE No.:
TEST ACCORDING TO:- ASME V
MATERIAL :
ACCEPTANCE STANDARD:-ASME B31.1
WPS No.:
INSPECTED LENGTH:
THK.:
EXAMINATION PROCEDURE NO.:
REV:
Reinforcement:
DATE:
WELD TYPE :-
S.
N.
DRAWING
NUMBER
WELD
NO.
WELDER
STAMP
BUTT
FILLET
INSPECTION PROCEDURE
FIT.
UP
DEFECTS
Welding
RESULT ELEC./Rod TYPE
FINAL
INSPECTION
REMARKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
C
CRACK
REMARKS :
FOR SUPPORT
F
FREE
P
POROSITY
S
SURFACE SLAG
UC
UNDER CUT
WS
WELD SPATTER
CHECK DIMENSION AND LEVEL
CHECK ALIGNMENT
SKETCH { IF REQUIRED } :
KAH.
AWPT QC:
Q.C
NAME:
SIGN.:
LEVEL:
DATE :
ILF QC:
NWC :
NAME:
SIGN.:
NAME:
SIGN.:
DATE :
DATE :
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