In Service Weld Repairs In Service Weld Repairs

Service repairs Other factors to be taken into consideration:

 Can be of a very complex nature, as the
component is very likely to be in a different
welding position and condition than it was during
production.
 It may also have been in contact with toxic, or
combustible fluids hence a permit to work will
need to be sought prior to any work being
carried out.
 The repair welding procedure may look very
different to the original production procedure
due to changes in these elements.
Effect of heat on any surrounding areas of the
component ie electrical components, or materials that
may become damaged by the repair procedure.
This may also include difficulty in carrying out any
required pre or post welding heat treatments and a
possible restriction of access to the area to be
repaired.
For large fabrications it is likely that the repair must
also take place on site and without a shut down of
operations, which may bring other elements that need
to be considered.

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Weld Repairs Weld Repairs

There are a number of key factors that need to be  What will be the effect of welding distortion and
considered before undertaking any repair: residual stress?
 The most important - is it financially worthwhile?
 Will heat treatment be required?
 Can structural integrity be achieved if the item is
repaired?  What NDE is required and how can acceptability
 Are there any alternatives to welding?
of the repair be demonstrated?
 What caused the defect and is it likely to happen again?  Will approval of the repair be required – if yes,
 How is the defect to be removed and what welding how and by whom?
process is to be used?
 What NDE is required to ensure complete removal of the
defect?
 Will the welding procedures require approval/re-
approval?

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Weld Repairs Weld Repair Decision Tree

 Use of approved welders. Has nature of NO NDE + Determine the Determine welding
the defect been Destructive filler material standards
 Dressing the weld and final visual. determined? tests

 A NDT procedure/technique prepared and carried YES Train the Qualify the
welder welder
out to ensure that the defect has been successfully Is repair the Replace
removed and repaired. right decision? NO the part NO

 Any post repair heat treatment requirements. Is welder

qualified?
Establish repair
procedure
Determine base Choose the
 Final NDT procedure/technique prepared and metal weldability welding process YES
carried out after heat treatment requirements.
Perform welding Prepare the
Inspection
 Applying protective treatments (painting etc as repair defect area
required). Has repair been NO
Procedure problem Fix problem
successful?
 (*Appropriate’ means suitable for the alloys being
YES
repaired and may not apply in specific situations) Protect and
return to service Welder problem

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