PT.

Hitachi Construction Machinery Indonesia

Standard Procedure Responsible Procedure No. Revision
WELDING REPAIR Department WRP.006.HCMI.03 No.
PROCEDURE Engineering 0

WELDING REPAIR PROCEDURE

OF
BOILER

Item No :-
Client :-
End User :-
Project Name :-
Project No. :-
Your P.O. No. :-
Our Job. No. :-

0 Issued for approval Nico Mahdi Suroso

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PT. Hitachi Construction Machinery Indonesia
Standard Procedure Responsible Procedure No. Revision
WELDING REPAIR Department WRP.006.HCMI.03 No.
PROCEDURE Engineering 0

Rev. No. Description Prepared Checked Approved

1. General

This Specification covers the welding defects repair detected by visual, dimensional
and the N.D.T applicable procedures.

2. References
Repair shall be complied with the requirements of the following codes, standards and
Purchaser requirements.

ASME section I, 2001 edition and 2002 addenda

ASME section II, 2001 edition and 2002 addenda

ASME section V, 2001 edition and 2002 addenda

ASME section IX, 2001 edition and 2002 addenda

3. Application

3.1 Elimination of Surface Defects Without Welding (Minor Defects)

Weld metal surface defects may be removed by grinding or machining and shall
not be repaired by welding provided the requirements as follow:
3.1.1 The remaining thickness of section is not reduced below that required.
3.1.2 The depression after defect elimination is blended uniformly into
surrounding surface.
3.1.3 The area examined after blending by magnetic particle or liquid penetrant
method meet the requirements of applicable codes to ensure that the
defect has been removed or indication reduced to an acceptable limit.

3.2 Defect Removal in Repair by Welding (Major Repairs)

3.2.1 Unacceptable defects detected visually or by NDT controls shall be
removed by mechanical or thermal gouging process, the area to be
prepared for repair shall be examined and will comply with the
requirements of NDT procedures.
3.2.2 Grinding after arc gouging and prior to repair welding shall eliminate a
minimum of 1.6 mm of base material.
3.2.3 When the distance of subsequence defects will be less than 50 mm, will
be repaired together.
3.2.4 If the defects to repair are any type of cracks, always will be made a
ultrasonic control of the defects in the adjacent area, to ensure that there
is not any type of micro cracks, before to start to repair.
3.2.5 After the repair done, the surface shall be blended uniformly into the
surrounding surface.
3.2.6 The weld repair shall be in accordance with applicable code and
submitted to the purchaser for approval.

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PT. Hitachi Construction Machinery Indonesia
Standard Procedure Responsible Procedure No. Revision
WELDING REPAIR Department WRP.006.HCMI.03 No.
PROCEDURE Engineering 0

3.2.7 The examination of weld repair(s) shall be repeated as required for the
original welds including 4 inches on each end of the repair.

3.3 Detailed Repair Procedure

3.3.1 All essential variables used in the welding repair shall be in accordance
with the applicable SMAW or GTAW welding procedure, latest approved
edition.
3.3.2 Overlap or Excessive Convexity.
These defects shall be reduced by removal of excess weld metal by
grinding.

Grinding

3.3.3 Excessive concavity of welds or craters, under cutting (0.8 mm over).

These defects shall be cleaned and deposited additional weld metal.
Undercuts less than 0.8 mm shall be cleaned by grinding.

Weld Grinding

Exposure Additional Weld Finish

3.4 Internal Defects

These defects shall be carried out to the following sequence.

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PT. Hitachi Construction Machinery Indonesia
Standard Procedure Responsible Procedure No. Revision
WELDING REPAIR Department WRP.006.HCMI.03 No.
PROCEDURE Engineering 0

PT or MT Weld

Exposure Remove Repair Weld NDE

Step 1. Elimination of Defects

The defects shall be removed by chipping, grinding, machining or arc-air
gouging when arc-air gouging is used, the gouged surface shall be ground
to clean metal surface.
Step 2. Examination on the Repair Welding Defects.
After defects elimination, the area shall be re- examined by magnetic
particle method or liquid penetrant method to ensure that defects have been
removed. Qualified NDE personnel and the qualified NDE procedures shall
perform the examination.
Step 3. Repair Welding.
The repair welding shall be performed in accordance with an approved and
qualified WPS in this specification. Qualified welders shall perform this
welding. After repair welding, the surface shall be blended uniformly into
the surrounding surface.
Step 4. Examination on the Repair Welds.
The examination required for the original weld or the base material shall be
repeated for the weld repair. The examination shall be performed by the
qualified NDE personnel and qualified NDE procedures.

4. Documentation
All welding repair shall be documented.

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