Production Impact Test Plate for Repair Welds
Production Impact Test Plate for Repair Welds
(OP)
I have two potential weld repairs.
Repair No. 1: I have welded a Category A joint with the SAW welding process. It was determined by UT that there is linear indication about 1/8 in. under the service and about 2 in. long. I was considering repairing it with FCAW, however since it is Category A, per UG-84(i)(1), I would have to run a production impact test plate using the FCAW process. Is this a correct interpretation? Also, the vessel thickness is approx. 8 3/8 in. thick. Do I have to weld this thickness for the production impact test plate or can I use a smaller thickness, such as 1.5 in., test plate?
Repair No. 2: There are small repairs on base metal of this vessel on a bevel preparation. The bevel preparation on one vessel will be welded to another bevel preparation on another vessel to create a Category B weld joint, which would require a production impact test plate at the time of welding this joint per UG-84(i1). Would I need to perform a production impact test plate to perform these repairs on a bevel preparation prior to it becoming a Category B joint? (Note: I understand that I can use the production impact test plate, if needed, for Repair No. 1 for this repair, if required).
Repair No. 1: I have welded a Category A joint with the SAW welding process. It was determined by UT that there is linear indication about 1/8 in. under the service and about 2 in. long. I was considering repairing it with FCAW, however since it is Category A, per UG-84(i)(1), I would have to run a production impact test plate using the FCAW process. Is this a correct interpretation? Also, the vessel thickness is approx. 8 3/8 in. thick. Do I have to weld this thickness for the production impact test plate or can I use a smaller thickness, such as 1.5 in., test plate?
Repair No. 2: There are small repairs on base metal of this vessel on a bevel preparation. The bevel preparation on one vessel will be welded to another bevel preparation on another vessel to create a Category B weld joint, which would require a production impact test plate at the time of welding this joint per UG-84(i1). Would I need to perform a production impact test plate to perform these repairs on a bevel preparation prior to it becoming a Category B joint? (Note: I understand that I can use the production impact test plate, if needed, for Repair No. 1 for this repair, if required).





RE: Production Impact Test Plate for Repair Welds
Yes.
You can qualify for a partial penetration weld deposit thickness needed for repair on 1.5" thick coupon, see QW-202 (b)
(b) Qualification for Partial Penetration Groove Welds.
Partial penetration groove welds shall be qualified in accordance
with the requirements of QW-451 for both base
metal and deposited weld metal thickness, except there
need be no upper limit on the base metal thickness provided
qualification was made on base metal having a thickness
of 11/2 in. (38 mm) or more.
Use the above for any weld repairs.
RE: Production Impact Test Plate for Repair Welds
RE: Production Impact Test Plate for Repair Welds
RE: Production Impact Test Plate for Repair Welds
In my opinion, the test plate needs to be the same thickness and from the same heat as the shell material.
RE: Production Impact Test Plate for Repair Welds
I was looking at Section IX, QW-202 (b) to qualify as a partial penetration weld, aka repair weld. The test plate must be of the same heat but does not need to be full thickness.
RE: Production Impact Test Plate for Repair Welds
QW-202.2(b) only applies to welding procedure qualification, which allows you to use a 1.5" thick test coupon to qualify the WPS. It appears the OP already has qualified a welding procedure for FCAW.
UG-84(I) applies to production impact test plates. UG-84(g) clearly indicates that impact test plates are in addition to the procedure qualification test plates. Two different plates with different requirements. The way I read it, UG-84(I) requires that impact test plates to be the same thickness and come from the same heat as the vessel component.
Newweldeng09: Have you discussed this with your AI?
RE: Production Impact Test Plate for Repair Welds
I would stick with the SAW for repair versus switching welding process midstream.
RE: Production Impact Test Plate for Repair Welds
This reasoning applies to Repair #2 as well. UG-84(I) requires impact tests of welds and HAZ for each qualified WPS used on the vessel. Therefore, you would not need to perform an additional production impact test plate on Repair #2 as long as the WPS for the bevel repair is the same as the one used to make the Category B weld.