# Weld Repair Procedure Template > Source: https://netray.co/tools/weld-repair-procedure-template > Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems. > Section: Free Tools ## Short answer Document a weld repair from defect location through excavation, rewelding, NDE and sign-off, then export it as a clean controlled document. ## Category quality ## Industry Fabrication ## Audience - Welding engineer - Quality engineer - Fabrication shop manager ## Tool **Kind:** template **Output:** document **Fields:** #### Company name **Key:** company **Type:** text **Default:** Northfield Fabrication Ltd #### Repair procedure number **Key:** repair_no **Type:** text **Default:** WRP-2026-014 #### Date **Key:** date **Type:** date **Default:** 2026-10-20 #### Job or work order **Key:** job_no **Type:** text **Default:** WO-48213 #### Weld or joint ID **Key:** weld_id **Type:** text **Default:** W-112 (shell to nozzle N3) #### Base material **Key:** base_material **Type:** text **Default:** SA-516 Gr 70, 25 mm thick #### Defect type **Key:** defect_type **Type:** select **Options:** - Lack of fusion - Porosity - Slag inclusion - Crack - Undercut - Incomplete penetration - Other **Default:** Lack of fusion #### Found by **Key:** defect_found_by **Type:** select **Options:** - Visual - RT - UT - MT - PT - Hydrotest - In service **Default:** UT #### Defect location and size **Key:** defect_desc **Type:** textarea **Default:** Planar indication 38 mm long, 6 mm through-wall height, located 120 mm from the start of the seam. #### Defect removal method **Key:** removal_method **Type:** select **Options:** - Grinding - Air carbon arc gouging then grinding - Machining - Plasma gouging then grinding **Default:** Air carbon arc gouging then grinding #### Repair WPS number **Key:** wps_no **Type:** text **Default:** WPS-021 Rev 3 #### Preheat and interpass **Key:** preheat **Type:** text **Default:** Preheat 100 C minimum, interpass 250 C maximum #### NDE after repair **Key:** nde_after **Type:** text **Default:** MT of excavation before welding, UT and MT of finished repair #### Repair attempt number **Key:** repair_limit **Type:** select **Options:** - First repair - Second repair - Third or more (needs engineering approval) **Default:** First repair **Blocks:** #### Weld Repair Procedure {{repair_no}} **Body:** Company: {{company}} Date: {{date}} Job / work order: {{job_no}} Weld ID: {{weld_id}} Base material: {{base_material}} Repair attempt: {{repair_limit}} #### 1. Defect description **Body:** Defect type: {{defect_type}} Detected by: {{defect_found_by}} {{defect_desc}} #### 2. Defect removal and excavation **Body:** Method: {{removal_method}} The excavation shall be shaped with smooth contours and a bevel suitable for access. Remove all carburized or oxidized surface material by grinding. Confirm complete defect removal with MT or PT before any welding starts. Record final excavation length, width and depth. #### 3. Repair welding requirements **Body:** Repair WPS: {{wps_no}} Preheat and interpass: {{preheat}} Use only welders qualified for the WPS, consumables from controlled storage, and the same or a compatible filler metal as the original weld. Record each pass in the weld traveler. #### 4. Examination after repair **Body:** {{nde_after}} Acceptance criteria are those of the governing code or the customer specification for the original weld. #### 5. Excavation and repair record **Table:** **Columns:** - Item - Requirement - Actual - Initials **Rows:** **0:** Excavation length (mm) **0:** Excavation depth (mm) **0:** MT/PT of excavation **1:** No relevant indication **0:** Welder ID **0:** Final NDE result **1:** Accept #### Approvals **Signatures:** - Welding engineer - Welding inspector - Quality manager - Customer representative (if required) **Notes:** A starting point, not a substitute for the governing code (for example ASME, AWS D1.1 or EN ISO 5817 acceptance rules) or your customer's contract. Check whether the repair needs customer notification or a requalified WPS. Some codes limit the number of repair attempts on the same location. ## Content **Intro:** A weld repair done without a written plan is how a ten minute fix becomes a rejected vessel. This template lays out the repair in the order an inspector will check it: defect, removal, procedure, examination and approval. Fill in the fields and export a controlled document. **Sections:** #### How to use the template **Body:** Complete the identification fields first, then describe the defect using the NDE report as the source. Choose the removal method that your shop actually uses and the WPS that covers the base material and thickness at the excavation depth. Export to PDF for the traveler or to Word if the quality department needs to add pages of sketches. Attach the NDE report that found the defect and the weld map that locates it. **Bullets:** - One repair procedure per defect location or per cluster of related defects - Attach the original NDE film, report or UT data reference - Print the excavation record table and fill it in at the bench - Keep the signed copy with the job data book #### The method behind a good repair **Body:** Repairs follow four steps in every major code: find the full extent of the defect, remove it completely, reweld with a qualified procedure, and re-examine to the same or stricter standard than the original weld. The step most often skipped is proving complete removal before welding. MT or PT of the excavation is cheap compared with welding over a remaining crack tip. Heat is the second risk. Gouging and welding both put heat into material that already has a weld heat affected zone, so preheat and interpass limits matter more on repairs than on first pass production. #### Reading the example **Body:** The default data describes a lack of fusion indication found by UT in a 25 mm carbon steel shell weld. The repair removes the flaw by gouging and grinding, welds with a procedure that has preheat of 100 C, then repeats UT and MT. If the same location had already been repaired once, the template prompts you to flag it, because many specifications require engineering or customer approval for a second attempt. Change the defect type and removal method to match crack repairs, which usually need tighter control and hydrogen management. #### Common mistakes **Body:** Most nonconformances on repairs come from paperwork gaps rather than welding skill. Avoid these before the inspector finds them. **Bullets:** - Welding the repair with a WPS that does not cover the thickness of the excavation - No record of excavation size, so the repair cannot be shown to be within limits - Skipping preheat because the part is already warm from gouging - Reusing a weld map number so the repair cannot be traced to the original joint - Failing to count repair attempts per location **Cta:** If your weld traveler and repair records live in an ERP or MES, we can help route repair procedures through the same approval workflow and link them to the work order. **Faq:** #### Does a weld repair need its own WPS? **Answer:** Not always. Repairs are normally made with a WPS that is already qualified for the base metal, filler and thickness range involved. The repair procedure references that WPS and adds the excavation, examination and approval steps. A new qualification may be needed if the repair changes essential variables. #### How many times can the same weld be repaired? **Answer:** It depends on the governing code and your customer. Many specifications allow one repair without special approval and require engineering or customer sign-off for a second attempt. Check the contract and code, and record the attempt number each time. #### Should the excavation be tested before rewelding? **Answer:** Yes, in most practice. MT or PT of the excavation confirms the defect is fully removed and that gouging has not left carburized layers or new cracks. It is far cheaper to find a remaining defect before welding than after final NDE. #### Can I edit the exported document? **Answer:** Yes. Export to Word to add sketches, photos or company numbering, or to PDF for a fixed copy. The template is a generic starting point, so adapt headings to match your quality system. ## Search terms weld repair procedure template, weld repair procedure format, weld repair plan, weld defect repair procedure, weld repair record, weld excavation and repair procedure, repair weld WPS reference --- Talk to an engineer: https://netray.co/contact?intent=erp_ai | Machine catalog: https://netray.co/agent/catalog.json