Repair Welding of Structures
Duraton: 5 Days
Format: Instructor-led with case studies, technical discussions, and practcal exercises
Course Overview
Repair welding is a critcal element of asset integrity management in the oil & gas industry. Pipelines,
pressure vessels, storage tanks, and offshore structures ofen face damage due to fatgue, corrosion,
cracking, or operatonal wear. This intensive 5-day course provides engineers and technical staff with
the knowledge and practcal tools to plan, execute, and control weld repairs safely and effectvely in
compliance with internatonal codes and standards.
Target Audience
• Maintenance & Reliability Engineers
• Welding & Fabricaton Engineers
• Inspecton & QA/QC Engineers
• Asset Integrity & Project Engineers
• Supervisors involved in repair and maintenance actvites
Course Objectves
By the end of the course, partcipants will be able to:
• Understand the fundamentals of repair welding metallurgy and failure mechanisms
• Select appropriate welding processes, consumables, and procedures for repair situatons
• Apply internatonal codes and standards (ASME, API, AWS) in repair welding practces
• Develop and qualify Welding Procedure Specifcatons (WPS) for repairs
• Plan and supervise in-service and shutdown repair welding actvites
• Implement inspecton, NDT, and quality assurance in repair projects
• Assess safety, risks, and integrity management during repair works
Course Agenda (Summary)
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 fller metal selecton
• Demonstraton: process & consumable selecton
Day 3 – Codes, Standards & Procedure Development
• ASME, API, AWS requirements for repairs
• Developing WPS, PQR, and welder qualifcaton
• Workshop: drafing a WPS for a repair case
Day 4 – Repair Executon & Quality Assurance
• Repair techniques for pipelines, vessels, tanks, offshore structures
• In-service welding, hot tapping, sleeve repairs
• NDT, inspecton, and QA/QC planning
Day 5 – Safety, Risk Management & Case Studies
• Safety in repair welding & confned space hazards
• Risk-based inspecton and ftness-for-service (API 579)
• Group exercise: developing a repair plan for an oil & gas case study
Training Methodology
The course combines interactve lectures, group discussions, real-world case studies, and practcal
exercises. Partcipants will gain both technical knowledge and hands-on experience in developing
repair strategies and procedures aligned with industry best practces.