Course Overview

Repair welding is a critical element of asset integrity management in the oil & gas industry. Pipelines, pressure vessels, storage tanks, and offshore structures often face damage due to fatigue, corrosion, cracking, or operational wear. This intensive 5-day course provides engineers and technical staff with the knowledge and practical tools to plan, execute, and control weld repairs safely and effectively in compliance with international codes and standards.

Target Audience

• Maintenance & Reliability Engineers
• Welding & Fabrication Engineers
• Inspection & QA/QC Engineers
• Asset Integrity & Project Engineers
• Supervisors involved in repair and maintenance activities

Course Objectives

By the end of the course, participants will be able to:

• Understand the fundamentals of repair welding metallurgy and failure mechanisms
• Select appropriate welding processes, consumables, and procedures for repair situations
• Apply international codes and standards (ASME, API, AWS) in repair welding practices
• Develop and qualify Welding Procedure Specifications (WPS) for repairs
• Plan and supervise in-service and shutdown repair welding activities
• Implement inspection, NDT, and quality assurance in repair projects
• Assess safety, risks, and integrity management during repair works

Course Agenda

Day 1 – Fundamentals of Repair Welding

• Role of repair welding in oil & gas
• Metallurgy and failure mechanisms
• Case studies of structural repairs

Day 2 – Welding Processes & Consumables

• SMAW, GTAW, GMAW, FCAW, SAW processes
• Consumable and filler metal selection
• Demonstration: process & consumable selection

Day 3 – Codes, Standards & Procedure Development

• ASME, API, AWS requirements for repairs
• Developing WPS, PQR, and welder qualification
• Workshop: drafting a WPS for a repair case

Day 4 – Repair Execution & Quality Assurance

• Repair techniques for pipelines, vessels, tanks, offshore structures
• In-service welding, hot tapping, sleeve repairs
• NDT, inspection, and QA/QC planning

Day 5 – Safety, Risk Management & Case Studies

• Safety in repair welding & confined space hazards
• Risk-based inspection and fitness-for-service (API 579)
• Group exercise: developing a repair plan for an oil & gas case study

Training Methodology

The course combines interactive lectures, group discussions, real-world case studies, and practical exercises. Participants will gain both technical knowledge and hands-on experience in developing repair strategies and procedures aligned with industry best practices.