Weld Repair Procedure Template
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.
Fill in
Weld Repair Procedure Template
Weld Repair Procedure WRP-2026-014
Company: Northfield Fabrication Ltd Date: 2026-10-20 Job / work order: WO-48213 Weld ID: W-112 (shell to nozzle N3) Base material: SA-516 Gr 70, 25 mm thick Repair attempt: First repair
1. Defect description
Defect type: Lack of fusion Detected by: UT
Planar indication 38 mm long, 6 mm through-wall height, located 120 mm from the start of the seam.
2. Defect removal and excavation
Method: Air carbon arc gouging then grinding
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
Repair WPS: WPS-021 Rev 3 Preheat and interpass: Preheat 100 C minimum, interpass 250 C maximum
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
MT of excavation before welding, UT and MT of finished repair
Acceptance criteria are those of the governing code or the customer specification for the original weld.
5. Excavation and repair record
| Item | Requirement | Actual | Initials |
|---|---|---|---|
| Excavation length (mm) | |||
| Excavation depth (mm) | |||
| MT/PT of excavation | No relevant indication | ||
| Welder ID | |||
| Final NDE result | Accept |
Approvals
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.
Route weld repairs through your ERP
Ask for a short review of how repair approvals and traceability could run from your work order system.
Optional. The tool and every export work without this. No spam.
How to use the template
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.
- 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
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
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
Most nonconformances on repairs come from paperwork gaps rather than welding skill. Avoid these before the inspector finds them.
- 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
Frequently Asked Questions
Does a weld repair need its own WPS?
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?
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?
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?
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.
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.
Related Tools
Welding Nonconformance Report Template
Record a weld nonconformance with defect details, applicable clause, root cause, disposition and sign-offs, then export a clean NCR.
Quality & InspectionNDT Weld Inspection Request Template
Request RT, UT, MT or PT on specific weld joints with the standard, acceptance criteria and readiness details the NDT technician needs.
Quality & InspectionWeld Joint Log and NDE Tracking Worksheet
Track each weld joint, its required NDE percentage and result, and see how much weld length still needs examination.
Engineering & PLMWelding Heat Input Calculator
Compute arc energy and net heat input from amps, volts, travel speed and process efficiency, and see how speed changes the result.
More Quality & Inspection tools
See all- WPS Template (Welding Procedure Specification)
- PQR Template (Procedure Qualification Record)
- Weld Inspection Checklist (Before, During and After Welding)
- Welding Consumables Issue Log Worksheet
- SAP QM Process Capability Cp Cpk Calculator
- SAP QM Lot Rejection Rate, PPM and Sigma Level Calculator
- SAP QM Gauge R&R Study Calculator
- SAP QM Cp and Cpk Capability Calculator
- Job Shop Material Certification Log Worksheet