Weld Repair Procedure

Weld joint which do not meet the specific requirements shall be repaired or cut out.
Zavareni spoj koji ne zadovoljava specifične zahtjeve treba popraviti ili izrezati.

On each weld joint which requires repair, the faulty area shall be clearly marked. The marking
shall not be removed until the defect has been repaired and the repair work has been inspected
Na svakom zavarenom spoju koji zahteva popravku, reparaturna površina mora biti jasno označena. Oznaka se
ne sme ukloniti dok se defekt ne popravi i ne ispita adekvatnom tehnikom ispitivanja bez razaranja.

If a defect, which requires repair, exceeds more than 20 % of the total weld lenght, or if several
defective weld section amount to 20% of the total weld lenght, the weld joint in question shall be
cut out and re-welded.
Ako defekt, koji zahteva popravku, prelazi više od 20% ukupne dužine zavara, ili ako nekoliko defekata zavara
iznosi 20% od ukupne dužine zavarivanja, predmetni zavareni spoj mora biti izrezan i ponovo zavaren.

Weld joints whit cracks shall be completely cut out

Zavareni spojevi sa pukotinama moraju biti potpuno izrezani

The lenght of excavation shall exceed the length of the defect by 30 mm at either end and the top
width shall be a minimum 15 mm.
Dužina iskopa mora biti veća od 30 mm na bilo kojem kraju, a gornja širina mora biti najmanje 15 mm.

min. 30 mm
Defect

min. 30 mm

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The depth of grinding the area must be more than the depth over meeting the defect from 1.0 mm
to 3.0 mm.
Dubina brušenja mora biti veća od dubine u odnosu na gresku od 1,0 mm do 3,0 mm.

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 60°±5°

Defect

min. 1.0-3.0 mm

Allowed conduct of three type of repair:through, partial and cup.- single layer repair is not alowed.
Dozvoljeno sprovođenje tri vrste popravaka: kroz, delimično i zavrsni. – izvodenje popravke u jednom sloju nije
dozvoljeno.

60°±5°
60°±5°

1.0-2.0 mm
14°
3.0-5.0 mm min 4 mm
Kroz / through Delimično / partial

Through thickness repair should be done if the defect is located at the depth less than 4 mm from
the internal surface of the pipe independently of the thickness of the pipe.
Popravka kroz celu debljinu treba izvršiti ako se greska nalazi na dubini manjoj od 4 mm od unutrašnje površine cevi,
nezavisno od debljine cevi.

60°±5°

min 4 mm
Repair shall be reteste non-destructively using suitable tehniques
Popravke treba testirati bez razaranja koristeći odgovarajuće tehnike

Marked area on the basis of appropriate weld test report, remove defective weld area, or accordint
to `` Reparation report`` - IM-003.
Oznaceno podrucje na osnovu odgovarajuceg izvestaja o ispitivanju zavarehnih spojeva , izvrsiti uklanjanje
defektne oblasti zavara, ili na osnovu ``Izveštaj o reparaturi`` - IM-003.

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At the marked place for repairing the weld joint with grinding maschine, grinding and cutting disc,
proceed to remove the defect area, however, care must be taken not to bring the material into the
area of the blue zone (overheating during removing the defect area).
Na obelezenom mestu oznacenom za popravku zavarenog spoja pomocu ugaone brusilice , brusne i rezne ploce
pristupiti uklanjanju defektne oblasti, stim sto se mora voditi racuna da se materijal ne dovede u oblast plave
zone ( pregrevanje prilikom uklanjanja greske).

If necessary, surface test methods can be used to determine that the identified fault in the weld
has been completely removed (Penetrant, megnetic particle).
Ukoliko je neophodno mogu se koristiti povrsinske metode ispitivanja kako bi se utvrdilo da je
identifikovana greska u zavaru kompletno uklonjena ( Penetranti , magneti ).

When removing a defect from a welded joint with grinding and cutting disc, care must be taken
not to impair the minimum thickness of the material , expecialy on the pipe wall.
Prilokom uklanjnja defekta iz zavarenog spoja sa brusnim i reznim plocama, mora se voditi racun da nedodje
do narusavanja minimalne debljine materijala , pogotovo kod cevi.

After removing the defective area, perform a visual inspection of the cut surface so that the
surface is smooth and without sharp notches.
Nakon uklanjanja defektne oblasti izvrsiti vizuelnu kontrolu izrezane povrsine da je povrsina glatka i bez ostrih
zareza.

Repair shall not be attempted more than twice

Popravka se ne sme pokušati više od dva puta;

The preparation of the area where the defect is removed must be adequately prepared for welding
such as in the sketch (at an angle of 60 ᴼ and with adequate distance at the root).
Pripremu oblasti na kojoj je izveseno uklanjenje defekta, mora se adekvatno pripremiti za zavarivanje kao sto je
da to na skici ( pod uglom od 60 ᴼ i adekvatnim rastojanje u korenu).
60°±5°
60°±5°

1.0-2.0 mm
min 4 mm 14°
3.0-5.0 mm

Clean the repair area from dirt and other contaminants, minimum 50 mm form the joint.
Očistite oblast za popravku od prljavštine i drugih nečistoća., mimimalno 50 mm od ivice spoja

Inspect the surface of the material for mechanical damage. Correct if available by grinding or re-
machining.
Pregledajte ivice materijala radi mehaničkih oštećenja. Ispravite ako je dostupno brušenjem ili ponovnom obradom.

Cleaning and Grinding: before start of weld – Preparation of the welding edge according to the
details of the preparation.
Čišćenje i brušenje: pre početka zavarivanja – Priprema ivice za zavarivanje prema detaljima pripreme.

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The stringer bead technique shall be used as far as possible, however bead width shall not be
larger than three times the size of the electrode or rod.
Tehnika bez njihanja dodatnog materijala treba da se koristi što je više moguće, ali širina njihanja ne sme biti veća od
tri puta veličine elektrode ili zice.

Preheating is performed in accordance with SRPS EN ISO 13916. The preheating temperature is
measured at a distance of A = 4xt mm, but not more than 50 mm from the edge of the welding (see
figure below). Intermediate temperature is measured directly on the weld metal or immediately
next to the base material.
Predgrevanja vrsiti u skladu sa SRPS EN ISO 13916. Marenje temperature predgrevanja se vrsi na udaljenosti A=4xt
mm , ali ne vise od 50 mm od ivice zljeba zavara (vidi sliku ispod). Medjuprolazna temperature se meri direktno na
metalu zavara ili odmah pored osnovnog materijala.

Provide cleaning with a grinding machine ( roto brush, cutting and grinding disc) between layer.
The interval between the root and hot passes is not more than 5 minutes. During the welding
process, pay attention to the conditions of preheating temperature and intermittent temperature.
Obezbedite čišćenje prolaza mašinom za brušenje (roto cetkom, reznom i brusnom plocom). Interval između
korenog i toplog prolaza nesme biti duži od 5 minuta. Prilikom izvođenja toplog prolaza obratiti posebno pažnju na
uslove temperature predgrevanja i međuprolazne temperature

It is forbidden to interrupt the welding and to allow the joint to cool down , before completion of
the root and hot pass.
Zabranjeno je prekidanje zavarivanja i dozvoljavanje da se spoj ohladi, pre nego sto se izvede koreni I topli
prolaz

Provide welding the filling and caps layers of the seam with the following rules:
Obezbediti zavarivanje popune i zavrsnog prolaza sa sledecim uslovima:

 Interlayer temperature control

 Kontrola međuslojne temperature
 Grinding of the starts and stops
 Zabrušivanja početka i kraja zavara (strat-stop)
 Grinding all Interlayer whit grinding machine – roto brush, cutting , grinding disc
 Čiščenje svih prolaza sa brusilicom- rotaciona četka, brusna i rezna ploca
 Consecutive or adjacent weld passes hall not be started at the same circumferential
position, the circumferential start locations of consecutive beads shall overlap by at least
20 mm.
 Uzastopni ili susjedni zavari se ne počinju u istom obodnom položaju, već se po obimu početne lokacije
slojeva zavara preklapaju najmanje 20 mm.

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 2

1
Preklapanje zavara
Overlap welds
 Weld start locations shall be grind to produce a smooth and tapered transition.
Mesta početka zavara moraju biti zabrušena kako bi omogućila da zavar bude gladak sa
ravnomernim prelazom.

BROJ ZAVARIVAČA : 1 – za sve prolaze

QUANTITY OF WELDERS: 1 – for all passes

LOKACIJA DEFEKTA: Oblelziti podrucje na osnovu adekvatnog IBR

izvestaja
LOCATION OF THE DEFECT Obtain the area on the basis of an adequate
NDT report

METODA ISPITIVANJA NAKON POPRAVKE 100% Vizuelno + adekvatna tehnika ispitivanja

(PT,MT,RT,UT)
TEST METHOD AFTER REPAIR 100% VT + adequate testing technique
(PT,MT,RT,UT)

NACIN UKLANJANJA DEFEKTA UGAONA / CEONA BRUSILICA

METOD OF REMOVING DEFECTS GRINDING MASCHINE