CONTRACT NO.

TANK DI01.1
REPAIR AND GLEANING SERVICES PBL-2017-056

ac
DOGUMENT NO.
5 Sheets
0O4IPROD/Proced ure/201 7

REPAIR PROCEDURE

22t08t2017 lssued for Review

I 1.l a
SGO YS DAB Approved Approved
Rev. Date Description
PT. GATRA KILANG PERSADA PETROGAS PETROGAS
 WELDING REPAIR PROCEDURE

TANK DIOl.l REPAIR AND CLEANING

SERVICES
GATRA
PBL-2017-056

TABULATTON OF REVISED SHEETS

R EVISION S REVISIONS
SHEET SHEET
A B C 0 1 4 c 0 1 2 3 4
1 x A1
2 x 42
3 43
4 44
5 X 4
6 X
7 47
I AA
I 4
10
11 51
52
1 5
14
15 55
th 5r
17 57
E 58
59
6r
1

h4
/t\ 65

)1
ht1
69
30 7

o 31 7
72
73
34 74
35 75
?6 76
77
7
39
40 80

1. PURPOSE
 WELDING REPAIR PROCEDURE

.1,
il,: I TANK D101-1 REPATR AND cLEANING
I SERVICES

PBL-2017-056

1-.1.This procedure cover repair of work of the weld defects and the surface on the base metal.
L.2.The repair work shall satisfy the requirement of ASME lX and Welding Procedure Speciflcations
(wPS).
1.3.Repair of each welding defect shall be based on the result of visual inspections or Non Destructive
Examinations.
1.4.This procedure also covers the minor repair of pitting corrosion plate and defect after removed of
tack weld on the shell plate.
1.5,Prior to witness inspection after defect repair by GKP, field-test and inspection shall be
performed and confirmed to satisfy the requirements of applicable code and specification.
1.6.Test and inspection defects to be witnessed are shown in quality of welding repair result,

o 2, SCOPE
2.1. Defects on the Welding
2.2. Material Defect

3. APPLICABLE CODE AND REFERENCE

3.1.ASME SECTION V "NON DESTRUCTIVE EXAMINATION"
3.2.ASME SECTION VIII DIV.l " RULES FOR CONSTRUCTION OF PRESSURE VESSELS"
3.3.ASME SECTION IX "BOILER & PRESSURE VESSEL CODE"
3.4, API STANDARD 550 "WELDED STEEL TANKS FOR OIL STORAGE"
3.5. CLIENT SPECIFICATION

4, RESPONSIBILITIES
GKP Welding Supervisor rresponsible to :

Arrange the welder to perform repair on the weld area and material
as per scope of work. GKP
Welding lnspector will be inspect the consumable to be use and weld area before and after finish
repa rr.
DEFECT ON THE PROCESS WETDING
o Porosity
e Pin Hole
o Slag lnclusions
o Lack of Fusion
o Under Bead Crack
o Under Cut
o Excess Reinforcement
. Excess Penetration
o Buttering or Weld Build-Up on Joints
NOTES:
For Storoge: Electrodes should be kept in closed storoge where prolonged exposure to sunroys and excessive
voriotions in temperature con be avoided. Once o con has been opened, the electrodes it contoins should
be used up os soon os possible.
5. DEFECT ON THE MATERIAL PLATE
 WELDING REPAIR PROCEDURE

I
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i-rr-i I rnrux D101-1 REPAIR AND CLEANING
_| SERVTCES

PBL - 2017 -056

Defect on the plates such as crack, pitting, gouge or tear according to recommendation after
inspection.
Defect of plate after removed temporary weld

5. PROCEDURE REPAIRS ON THE WELDING AND MATERIAL PTATE

Procedure Repoir on th
a. When defects, un-acceptable to specification are detected as result of testing and/or
inspection, the defective weld shall be repaired or removed.
b. Before welding repairs are made, injurious defects shall be entirely removed to sound
metal by are gauging, grinding, chipping or machining and checked by visual examination.
c. All slag and scale shall be removed.
d. The welding procedure to be used for repairing shall be in principle the applicable procedure
qualified.
e. Such repaired area shall be re radiographic or inspected by the same means previously
used.
f. The number or weld repairs of the same weld shall be taking two additional joints
for radiographic at most.
C. The repair welding shall be carried out by qualified welder using and approved by
Welding Procedure Specification (WPS).
h, The welding procedure to be used for repairing shall be in principle the applicable
procedure qualified.
Butterino or weld build-up on ioints:
a, Buttering or weld build-up on the prepared surface shall not exceed the lesser of 1.13 of the
base metalthickness.
b. The buttering shall be inspected by LP (Liquid Penetrant) or MT (Magnetic Particle Test)
after completion of the built-up but before f inal a welding of joint.
c, GKP welding inspector will be submit the electrode to be used for CLIENT review and
approval.
d. GKP also submit sketch of butter joint for CLIENT review and Approval.
e. WPS to be use for shall be approved by CLIENT.
f. Documentation requirement upon completion repair on welding area shall record by GKP.
P roced u re Re po i r M atelDl Plgls

a. Before repair are made, GKP will clean surface area to be repair with wire brush, grinding,
chipping or machining, make sure all corrosion will be removed from area to be repair.
b. After the entire defect have been clean and prepare the welding for repair of defect and
shall be checked by visually before welding.

c. The weld deposit overlay shall be qualified on base metal of the same composition.
d. Qualif ied welder will do the repair welding.
e. After repair by welding finish all area repairs will be smoothly grind and shall be checked
by GKP.
f. After finish repair mark material with "Repair OK".
 ^-4

WELDING REPAIR PROCEDURE

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...i I rANK D1o1-1 REpAtR AND cLEANING
i SERVICES gGAr
PBL-20',17-056

7. WELDING CONTROL
1) Welding Procedure
All welding procedures employed shall be in accordance with welding specification. All Welding
procedures shall be qualified in accordance with the approved Welding Procedure Specification
(WPS) by DISNAKER.
2l Welders
All weldersto perform welding shall have been qualified in accordance with the specification
and shall have a welder certificate approved by DISNAKER. A list of welders incorporating the result
and limits qualified such as positions, thickness, etc. shall be prepared by GKP.
3) Welding Consumables and Apparatus
Welding consumable used shall be ensured to be of the approved type's grades and
o appropriately stored. Welding electrodes shall be kept dried and protected. Holding ovens shall
be inspected regularly for proper function.
lf four (4) hours have passed after the electrodes have been taken out of the ovens and exposed
to the atmosphere, such electrodes shall be re-dried in the ovens.
Welding machines used shall be of sufficient capacity to produce desirable welds. Welders
shall also use proper apparatus and equipment.
Filler metal will be selection for diameter and manufacturing recommendation.
4) Welding Operation
o No welding shall start or contlnue when there is rain, strong wind (velocity of 10 m/
sec or over).
o Before starting any welding works, it shall be ascertained whether pre-heating is
necessary. Heating shall also be carried out when welding is resumed after stopping for
some time, when the work piece specifically requires pre-heating. lnter pass temperatures
control shall also be monitored. Temperature indicating crayons shall be used for pre-heating
purposes.
o On the operation of welding machine, GKP Welding lnspector shall be controlling to be
current, voltage and traveling speed.
o lnspect maximum thickness for each pass.
o All repairs welding will be start shall accordance to welding sequence to avoid any
deformation during repair.
o During repair of welding, identification number of each qualified welder who
performed welding works shall be recorded.
5) lnspection & Testing
o All welds shall be visually inspected after completion of weld.
. All butt joints shall have complete penetration and full fusion. The surface of the weld
shall be free of coarse ripples, grooves, overlaps, abrupt ridges or valleys.
Flux and slag shall be removed completely from weld beads and from the surface of
completed welds and adjoining base material.
o All testing include NDE, etc shall comply with the related standard and Specification.