Doc.

No : AS-PR-002
BASE METAL REPAIR Revision : 0
PROCEDURE
Date : 22 Nov 2021

1. SCOPE

1.1. This is a general repair procedure for materials, it covers the requirements, methods and
techniques for repair of defects in ferrous materials that will be used or has been used for
Code items designed and manufactured in accordance with the ASME Code Section VIII
Div.1 & Div. 2. This procedure does not include repair in cast iron material and material
containing more than 0.35% carbon. This procedure also does not include the repair for the
cracked and laminated materials.
1.2. Should any repair be necessary for cast iron material and material containing more than
0.35% carbon or any laminar-type discontinuities, or any cracked material, a particular repair
procedure shall be prepared and submitted to the Authorized Inspector for review and
acceptance before start repair of any defects.
1.3. Any defects come with the material if the magnitude exceeds the limits as specified by the
material specification, the material shall be rejected. However, if any rejected material is
proposed or to be repaired by welding, the approval from the client and acceptance by the
Authorized Inspector shall be obtained.
1.4. This procedure shall be used in conjunction with ASME Code Section II Part A and Section
VIII Div.1 & Div. 2.

2. REFERENCES

 ASME Code Section VIII Div. 1

 ASME Code Section VIII Div. 2
 ASME Code Section II Part A

3. RESPONSIBILITY

3.1. QC Inspector responsible to determine a part of rejected and perform visual inspection
before and after repair until a part accepted. Included witness NDE after repair if needed.

3.2. Welding Engineer responsible to provide Welding Procedure Specification (WPS) and other
relevant method repair and NDE.

3.3. Production Manager / Supervisor responsible to perform repair in accordance with

Procedure repair (WPS) with qualified welders and other relevant instruction repair method.

3.4. NDE Supervisor responsible to perform NDE after repair accordance with relevant
procedure/ requirement.
LATEST REVISION OF THIS DOCUMENT IS KEPT AT QMS DRIVE OF CLADTEK’S INTRANET SERVER. IT SHALL BE THE RECEIVERS
RESPONSIBILITY TO IDENTIFY AND CONTROL SUPERSEDED DOCUMENTS.
2 of 7| P a g e
 Doc. No : AS-PR-002
BASE METAL REPAIR Revision : 0
PROCEDURE
Date : 22 Nov 2021

4. TYPE OF IMPERFECTION DEFECTS

Following imperfections are considered as defects that maybe repaired either by grinding only or by
welding as per this procedure and applicable construction code and material specification:

4.1 Surface imperfections, such as seams, scabs, laps, tears, or slivers, chip marks, scratches,
blemishes, pressed dent, notches, or other irregularities that come with the materials are
considered as defects on the materials.

4.2 Surface imperfections such as chip marks, scratches, blemishes, notches undercuts, arc
strikes, gouge marks, grind marks, pressed dent, scars or irregular stub-ends or other
unacceptable irregularities caused by mechanical or thermo-process during fabrication of
Code items or parts thereof are considered as defects on the materials.

5. REPAIR BY GRINDING

All defective locations of the material shall be marked up and where necessary sketched through
visual examination before start grinding repair.
5.1. Repair by grinding for the plate shallow defects shall be ground to sound metal, the ground
area shall be well faired and the thickness of the ground plate shall not be reduced below
the minimum thickness permitted or less than the lower limitation of tolerance of the that
material specified by the material specification. All surface defects, the removal of which will
reduce the plate thickness below the minimum thickness permitted, shall be cause for
rejection of the plate, except that, by agreement with the Client and acceptance by the
Authorized Inspector, the metal so removed may be replaced with weld metal.
5.2. Repair by grinding for pipe (except of stainless steel and duplex pipe) defects commonly
referred to as scabs, seams, laps, tears, or slivers or other irregularities that are shallower
than 5% of the nominal wall thickness maybe repaired by grinding. When the defects are
removed by grinding, a smooth curved surface blending to the adjacent surrounding area
shall be maintained, and the wall thickness shall not be decreased below that permitted by
12.5% under the specified wall thickness. The outside diameter at the point of grinding is
permitted to be reduced by the amount so removed.
5.3. Repair by grinding or machining for forging materials surface defects such as chip marks,
blemishes, or other irregularities may be removed by grinding or machining, and the surface
exposed shall be blended smoothly into the adjacent surface when sufficient wall thickness
permits thin areas in compliance with the requirements of paragraph UF-30 for Certification
Mark with U Designator Code items and paragraph 6.7.4.1 for Certification Mark with U2
Designator Code items.

LATEST REVISION OF THIS DOCUMENT IS KEPT AT QMS DRIVE OF CLADTEK’S INTRANET SERVER. IT SHALL BE THE RECEIVERS
RESPONSIBILITY TO IDENTIFY AND CONTROL SUPERSEDED DOCUMENTS.
3 of 7| P a g e
 Doc. No : AS-PR-002
BASE METAL REPAIR Revision : 0
PROCEDURE
Date : 22 Nov 2021

5.4. Surface defect (s) such as undercuts, gouge marks and other unacceptable lacerations
caused by mechanical tools shall be removed by grinding. Arc strikes outside weld bevels
shall be carefully removed by grinding and these areas shall be 100% examined by magnetic
particle examination or liquid penetrant examination.

5.5. Shallow notches on bevel edges or base material surface shall be carefully ground to a
smooth contour. No direct repair welding is required on flame cut notches/ gouges on cut bevel
edges. These areas shall be ground to a smooth profile and shall be welded during normal
production welding. For deep notches/gouge marks 3 mm in depth, the groove geometry shall
be prepared in a manner that shall provide adequate access for repair welding. Special care
shall be taken to ensure that area is free from conditions that may result in slag inclusion, lack
of fusion & other weld imperfections. All repairs shall cover the full cross section of the
notches/gouges.

5.6. Examination of defective areas-Areas from which defects have been removed by grinding and
the minimum required thickness has been maintained shall be examined by either the
magnetic particle or by the liquid penetrant method in accordance with Appendix 6 and
Appendix 8 of ASME Code Section VIII Div. 1 for Certification Mark with U Designator Code
items and Part 7 of ASME Code Section VIII Div. 2 for Certification Mark with U2 Designator
Code items to ensure complete removal of the defect.

6. REPAIR BY WELDING

All defective locations of the material shall be marked up and where necessary sketched through visual
examination before start welding repair.

6.1. Any grinding to remove the surface defects beyond those permitted either by the applicable
construction code, or material specification or fabrication drawing may be repaired by
welding only after agreement by Client and acceptance by the Authorized Inspector unless
prohibited by the material specification.

6.2. Defects shall be removed to sound metal and verified by magnetic particle examination or
liquid penetrant examination for the ferromagnetic materials or by liquid penetrant
examination for non-ferromagnetic materials or by acid etch method to ensure complete
removal of the defect.

6.3. The ground area to be weld repaired shall be of smooth profile without sharp comer, notch
or valley and shall be of enough width and length to avoid any weld defects to be trapped
therein during weld repair.

6.4. The surfaces to be welded shall be clean and free of scale, rust, oil, grease, slag, detrimental
oxides, and other deleterious foreign material. The method and extent of cleaning should be
determined based on the material to be welded and the contaminants to be removed.

LATEST REVISION OF THIS DOCUMENT IS KEPT AT QMS DRIVE OF CLADTEK’S INTRANET SERVER. IT SHALL BE THE RECEIVERS
RESPONSIBILITY TO IDENTIFY AND CONTROL SUPERSEDED DOCUMENTS.
4 of 7| P a g e
 Doc. No : AS-PR-002
BASE METAL REPAIR Revision : 0
PROCEDURE
Date : 22 Nov 2021

6.5. Repair welding shall be carried out as follows:

6.5.1. The welding procedure and welders to be employed for the repair welding shall be
qualified in accordance with ASME Code Section IX and applicable construction
Code. Before commencement of any repair by welding, the base metal of areas
surrounding the defect for a minimum radius of 75mm shall be preheated to a
temperature at 50°C as a minimum or to the temperature stated in the designated
welding procedure specification whichever is higher.

6.5.2. If the base metal to be or used for Code item that requires impact testing then the
welding procedure shall be qualified so and shall meet the same minimum
requirements as established for the base material.

6.5.3. If the base metal used for Code item that requires post weld heat treatment (PWHT)
then the welding procedure shall be qualified so and shall meet the same minimum
requirements as established for the base material and the repair welding shall be
performed before conducting PWHT of the Code item.

6.5.4. If the forging material used for Code item to be fabricated in accordance with
ASME Code Section VIII Div. 1, the repair welding shall be post weld heat treated
when the weld repair exceeds 6 in.2 (4 000 mm2) at any spot or if the maximum
depth exceeds ¼ in. (6 mm) (see UF-37).

6.5.5. For Code item to be or was fabricated in accordance with ASME Code Section
VIII Div. 1, repair welding of forging materials shall be radiographed if the
maximum depth exceeds: win. (10 mm). Repair welds: Win. (10 mm) and under
in depth which exceed 6 in.2 (4 000 mm2) at any spot and those made in materials
requiring post weld heat treatment shall be examined by radiographing, magnetic
particle or liquid penetrant examination, or any alternative method suitable for
revealing cracks (see UF-37).

6.5.6. For liquid quenched and tempered forging steels, other than austenitic steels for
Certification Mark with U Designator Code items, welding repairs shall be in
accordance with UF-37 (b) (3).

6.5.7. Welding repairs of Certification Mark with U Designator Code item made of
forging material which is to be or have been liquid quenched and tempered,
regardless of depth or area of repairs shall have the repaired area radiographed
and examined by magnetic particle or liquid penetrant examination (see UF-37).

6.5.8. Any welding repair on the forging Code item to be fabricated in accordance with
ASME Code Section VIII Div. 2, repair welding shall be performed as per
paragraph 6.7.8 of the ASME Code Section VIII Div. 2 and applicable material
specification of ASME Code Section II Part A.
LATEST REVISION OF THIS DOCUMENT IS KEPT AT QMS DRIVE OF CLADTEK’S INTRANET SERVER. IT SHALL BE THE RECEIVERS
RESPONSIBILITY TO IDENTIFY AND CONTROL SUPERSEDED DOCUMENTS.
5 of 7| P a g e
 Doc. No : AS-PR-002
BASE METAL REPAIR Revision : 0
PROCEDURE
Date : 22 Nov 2021

6.5.9. Any welding repair on other materials for the Code item to be fabricated in
accordance with ASME Code Section VIII Div. 2, repair welding shall be
performed as per paragraph 6.1.1.3 of the ASME Code Section VIII Div. 2 and
applicable material specification of ASME Code Section II Part A.

6.5.10. Excess weld shall be ground flush with the adjacent surface preserving the same
configuration as the original material.

6.5.11. Any welding repair and followed heat treatment on the standard forging parts such
as flanges, nozzles, nozzle necks, nozzle saddles, and couplings etc. shall be
performed in accordance with applicable material specification and construction
Code.

6.5.12. Removal of temporary attachments the areas from which temporary attachments
have been removed shall be dressed smooth and shall be examined by the
magnetic particle method or liquid penetrant method in accordance Code
requirements. Defects shall be removed and the material shall be inspected to
ensure that the defects have been removed. If weld repairs are necessary, then
the repairs shall be made as per this procedure and the repairs shall be inspected,
examined and tested in accordance with the requirements of applicable
construction Code.

6.5.13. Surface weld metal build-up for Certification Mark with U Designator Code item:
a) Construction in which deposits of weld metal are applied to the surface of
base metal for the purpose of restoring the thickness of the base metal for
strength consideration; or modifying the configuration of weld joints in
order to provide the tapered transition requirements of UW-9 (c) and UW-
33 (b) shall be performed in accordance with the rules in (b) and (c).
b) Procedure Qualification. A butt welding procedure qualification in accordance
with provisions of Section IX shall be performed for the thickness of weld metal
deposited, prior to production welding.
c) Examination Requirements
(1) All weld metal build-up shall be examined over the full surface of the
deposit by either magnetic particle examination to the requirements of
Appendix 6, or by liquid penetrant examination to the requirements of
Appendix 8.
(2) When such surface weld metal build-up is used in welded joints which
require full or spot radiographic examination, the weld metal build-up shall
be included in the examination.

LATEST REVISION OF THIS DOCUMENT IS KEPT AT QMS DRIVE OF CLADTEK’S INTRANET SERVER. IT SHALL BE THE RECEIVERS
RESPONSIBILITY TO IDENTIFY AND CONTROL SUPERSEDED DOCUMENTS.
6 of 7| P a g e
 Doc. No : AS-PR-002
BASE METAL REPAIR Revision : 0
PROCEDURE
Date : 22 Nov 2021

6.5.14. Surface weld metal build-up for Certification Mark with U2 Designator Code item:
a) Construction in which deposits of weld metal are applied to the surface of base
metal for the purpose of restoring the thickness of the base metal or modifying
the configuration of weld joints in order to provide the tapered transition
requirements of paragraph 4.2 shall be performed in accordance with (b) and
(c).
b) Procedure Qualification. A butt welding procedure qualification in accordance
with the provisions of Section IX shall be performed for the thickness of weld
metal deposited, prior to production welding.
c) Examination Requirements
(1) All weld metal build-up shall be examined over the full surface of the
deposit by the magnetic particle or liquid penetrant method in accordance
with Part 7. This requirement does not apply to weld overlay.
(2) When such surface weld metal build up is used in welded joints that
require radiographic examination in accordance with Part 7, the weld
metal build up shall be included in this examination

6.5.15. Examination of finished weld - repaired surfaces

(1) The finished surface of the weld repair shall be prepared and inspected by either
the magnetic particle or by the liquid penetrant method in accordance with
Appendix 6 and Appendix 8 of ASME Code Section VIII Div. 1 for Certification
Mark with U Designator Code items and Part 7 of ASME Code Section VIII Div.
2 for Certification Mark with U2 Designator Code items.
(2) For weld repairs of material for Certification Mark with U2 Designator Code items,
all weld repairs shall be examined by radiography, by a magnetic particle method,
or by a liquid penetrant method, in accordance with the requirements of paragraphs
7.5.3, 7.5.6, or 7.5.7 of ASME Code Section VIII Div.2. Weld repairs shall be
radiographed when the depth of weld repair exceeds 10 mm (3/8 in.) or one-half
the material thickness whichever is less. The acceptability of the repair welds shall
be determined by the acceptance standards set forth in the applicable paragraph.
(3) The area repaired by welding shall also be subjected to required non-destructive
examinations as per the material specifications of ASME Code Section II Part A.

6.5.16. Defective material that cannot be satisfactorily repaired shall be rejected.

6.5.17. Heat treatment after welding repairs, should any heat treatment be required by
material specification of ASME Code Section II Part A and or by the applicable
construction Code, then the heat treatment shall be performed as per the Code
requirements.

7. DOCUMENTATION

All repairs to materials shall be documented as per Company's QC Control Manual. Where necessary,
the documentation shall also include sketches and the photos before and after repair.
LATEST REVISION OF THIS DOCUMENT IS KEPT AT QMS DRIVE OF CLADTEK’S INTRANET SERVER. IT SHALL BE THE RECEIVERS
RESPONSIBILITY TO IDENTIFY AND CONTROL SUPERSEDED DOCUMENTS.
7 of 7| P a g e