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RESPONSIBLE DEPARTMENT
Materials and Process Engineering (Hydro)

WRITTEN BY CHECKED BY APPROVED BY

Benoit DEMESMAY Kevin BALIDAS Gwenael BOUGARAN

SCOPE AND PURPOSE

This instruction shall be applied when a repair by welding is involved on:
• on welds,
• on parts or products,
• on base metal

The repair shall meet the same requirements as those applied to production welds.

This instruction shall be applied in the limits of 2 welding repairs at the same location. In case of more
than 2 repairs in the same location, a detail root cause analysis of the indication must be performed.
The manufacturer may not make further welds until he has prepared a report analyzing the cause of
these successive repairs and submitted it to MPE’s approval.

DOCUMENT REVISION CHART

DOCUMENT REVISION STATUS: DETERMINED BY THE LAST ENTRY IN THE “REV” AND “DATE” COLUMN

REV. SECTION MODIFIED AND REVISION DESCRIPTION DATE RELEASED BY

DD/MM/YYY

- First issue 31/07/2017 MPE Department (Hydro)

© Copyright 2017 – GE Renewable Energy. All rights reserved. Reproduction of any nature by any means, modifications,
use or disclosures to third parties without express authority is strictly forbidden.

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1 APPLICABLE DOCUMENTS ........................................................................................................................................................... 3

2 GRADE OF BASE METAL / WELD CONCERNED ............................................................................................................................ 3
3 WELDING QUALIFICATION (WPQR) ............................................................................................................................................ 3
4 OPERATOR QUALIFICATION ........................................................................................................................................................ 3
5 WELDING PROCESS SELECTION ................................................................................................................................................... 3
6 EXCAVATION METHOD................................................................................................................................................................ 3
6.1 MECHANICAL EXCAVATION ............................................................................................................................................... 3
6.2 THERMAL EXCAVATION: ARC GOUGING ........................................................................................................................... 4
7 WELDING REPAIR ........................................................................................................................................................................ 5
7.1 GENERAL CASE: BUTT WELD, FILLET WELD & BASE METAL .............................................................................................. 5
7.2 SPECIFIC CASE: OVERLAY WELDING .................................................................................................................................. 7
8 TEST AFTER WELDING REPAIR..................................................................................................................................................... 7
8.1 NON DESTRUCTIVE TESTING ............................................................................................................................................. 7
8.2 DESTRUCTIVE TEST ............................................................................................................................................................ 8
9 WELDING REPAIR PROCESS STEPS .............................................................................................................................................. 8
9.1 CARTOGRAPHY REPORT .................................................................................................................................................... 8
9.2 INDICATION REPORT ON THE PART ................................................................................................................................... 8
9.3 MARKING POSITION ON THE PART .................................................................................................................................... 8
9.4 CARTOGRAPHY ANALYSIS BEFORE GOUGING OPERATIONS ............................................................................................. 9
9.5 PREHEATING CONDITION FOR GOUGING.......................................................................................................................... 9
9.6 EXCAVATION SHAPE AFTER GOUGING / GRINDING .......................................................................................................... 9
9.7 CHECKING OF THE EXCAVATION DEPTH .......................................................................................................................... 10
9.8 GRINDING OF THE EXCAVATION ..................................................................................................................................... 10
9.9 SURFACE NON-DESTRUCTIVE TEST .................................................................................................................................. 10
9.10 TRACEABILITY OF EXCAVATIONS ..................................................................................................................................... 10
9.11 REPAIR BY WELDING ........................................................................................................................................................ 10
9.12 WELDING TRACEABILITY .................................................................................................................................................. 10
9.13 GRINDING REPAIRS .......................................................................................................................................................... 10
9.14 NON DESTRUCTIVE TEST.................................................................................................................................................. 10
10 APPENDIX 1: TRACEABILITY EXCAVATION SHEET ................................................................................................................ 11
11 APPENDIX 2: WELDING TRACEABILITY REPAIR .................................................................................................................... 12
12 APPENDIX 3: EXAMPLES ....................................................................................................................................................... 13

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1 APPLICABLE DOCUMENTS

The reference documents are listed below:

• EN 1011-2, Welding — Recommendations for welding of metallic materials — Part 2: Arc welding of ferritic steels.
• EN ISO 13916, Welding — Guidance on the measurement of preheating temperature, inter pass temperature and preheat
maintenance temperature.
• P8AHEM4100: Welded structure – Low alloy carbon steel
• P8AHEM4202: Welded structure – High strength steel quenched and tempered
• P8AHEM4500: Welded structure – Austenitic stainless steel
• P8AHEM4400: Welded structure – Martensitic stainless steel
• P8OHEM4710: Manufacturing guidelines - Martensitic stainless steel – Overlay Welding
• P8OHEM4720: Manufacturing guidelines - Austenitic stainless steel – Overlay Welding
• P8OHEM4730: Manufacturing guidelines - Cupro-Aluminum – Overlay Welding
• P10HEM5400: PWHT specification
• P3WHEM6100-31: weld inspection standard according ASME
• P3WHEM6100-01: weld inspection standard according EN

2 GRADE OF BASE METAL / WELD CONCERNED

This specification addresses the base metal grades / weld indicated just below:
• Austenitic stainless steel solution annealed
• Carbon steel normalized
• Martensitic stainless steel quenched and tempered
• High strength steel quenched and tempered
• High strength steel thermomechanical
• Martensitic stainless steel overlay
• Austenitic stainless steel overlay
• Cupro-aluminum overlay

More information is given their respective welding process specifications.

3 WELDING QUALIFICATION (WPQR)

A welding qualification (WPQR) shall be used for each welding repair. This WPQR can be accordingly EN ISO or ASME IX standard.

4 OPERATOR QUALIFICATION

Only qualified personal is allowed to perform welding repair. The certificate of the welder shall be updated an available at any
moment. Only authorized personal is allowed to perform arc gouging. An internal test can be done to prove operator’s skills.

5 WELDING PROCESS SELECTION

The welding process shall be adapted to the size of the excavation area. For small volume repair, SMAW and GTAW process are
recommended. For large volume repair, GMAW (FCAW or MCAW) are recommended.

6 EXCAVATION METHOD

6.1 MECHANICAL EXCAVATION

Mechanical devices can be used to perform excavation such as:

• Grinding wheel
• Rotator grinding
• Machining

In case of mechanical excavation on stainless steel, dedicated tool shall be used to avoid carbon pollution.

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6.2 THERMAL EXCAVATION: ARC GOUGING

Thermal devices can be used to perform excavation such as arc gouging.

All the recommendations and settings regarding arc gouging are detailed just below.

6.2.1 GENERALITIES

Arc gouging is considered as a thermal process like welding. Some requirements have to be applied:
• Pre-heating before starting the gouging on raw material such as martensitic stainless steel and high strength steel
quenched and tempered (refer to associated Welding Process Specification)
• Clean the excavation by mechanical device after gouging
• Clean all slags and projections created with gouging

The HAZ need to be removed during the cleaning of the excavation and it is requested to reach a clean white metal.

The geometry of this excavation shall respect recommendations just below and do not pollute sound weld area.

6.2.2 ELECTRODE DIAMETER

The electrode diameter shall be in accordance with the excavation to be done. Several diameters are available in the market.

6.2.3 LENGTH BETWEEN END ELETRODE AND TORCH

To have a full efficiency of the compressed air jet, the length between the end of the electrode and the torch is around 100 mm
(see picture just below).

6.2.4 ANGLE BETWEEN ELECTRODE AND PART

To have a good efficiency during the gouging of the part, the angle between the electrode and the part will between 30 and 45°
(see picture just below).

Around 100 mm

30 to 45°

6.2.5 AMPERAGE SETTING

All the gouging electrodes are used in direct current DCEP (DC+), with the electrode at the positive pole.
The current value is set according to the electrode diameter. Find a table which give indication on current, to help the worker to
set parameters according to the diameter.

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6.2.6 GOUGING SPEED

The gouging speed (movement of the hand of the worker) is link to:
• Couple of electrode diameter and intensity
• Accessibility
• Position

The gouging speed is well set up when those factors are controlled:
• Arc stable
• Short-circuit is limited
• Very Few liquid metal (carbon oxide) deposit

6.2.7 COMPRESSED AIR PRESSURE

The pressure of the compressed air shall be around 5 bars (80 PSI) to have a good efficiency during gouging. The compressed air
need to be filtered and clear of oil and humidity.

7 WELDING REPAIR

7.1 GENERAL CASE: BUTT WELD, FILLET WELD & BASE METAL

7.1.1 WELDING REPAIR BEFORE PWHT

Rules to apply for repair before PWHT are the same as the original welds.

7.1.2 WELDING REPAIR AFTER PWHT

In general, repair by welding after final heat treatment is forbidden.
However, repairs which may be carried out are subjected to the Material and Process Engineering department approval provided
that the welding procedure has been covered by a special qualification test and satisfies all the requirements of following
paragraph:

• The repair procedure shall indicate the number, size and relative location of the excavations.

• The repair shall be carried out with a qualified arc welding procedure whereby a low hydrogen weld metal is deposited
in stringer beads.

• The metal shall be removed by mechanical means.

• The preheat temperature of the area to be repaired by welding shall not be less than that of the Welding Process
Qualification Record.

• The energy parameters prescribed in the weld procedure shall be monitored during the entire welding operation.

• The second layer of weld metal shall be deposited in order to ensure tempering of the heat affected zone in the base
metal caused by the first bead. Similarly, after filling, additional beads shall be deposited on top of the last layer without
overlapping the base metal in order to ensure tempering of the heat affected zone in the base metal caused by the last
layer to be deposited. This technic is named “Temper bead” (see sketch just below)

• Post heating operation shall be performed as required by Welding process specification

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7.2 SPECIFIC CASE: OVERLAY WELDING

7.2.1 AUSTENITIC STAINLESS STEEL

The same rules apply as a usual welding operation.

7.2.2 MARTENSITIC STAINLESS STEEL

In this case, several methods of welding repair can be applied.

• Repairs affecting the base metal

o On the chamfer
▪ A buttering is needed in austenitic stainless steel on the base metal
▪ The filling of the rest of the excavation is done in martensitic stainless steel

o Inside the overlay

▪ A buttering is needed in the end of the excavation in austenitic stainless steel
▪ The filling of the rest of the excavation is done in martensitic stainless steel

• Repairs non-affecting the base metal

o The filling of the rest of the excavation is done in martensitic stainless steel

7.2.3 COPPER ALUMINUM

The welding repair on Copper Aluminum overlay is recommanded with a WPQR qualified with GTAW process. It can also be done
in GMAW. All the other requirements of initial welding of Cu-Al shall applied.

8 TEST AFTER WELDING REPAIR

Control of welded joint needs to be done according to a specific procedure:

• P3WHEM6100-31: weld inspection standard according ASME
• P3WHEM6100-01: weld inspection standard according EN

8.1 NON DESTRUCTIVE TESTING

Material grade ASME GROUP n° EN GROUP n° Timing of performance

Austenitic stainless steel 8(1) 8.1
Duplex stainless steel 10H(1) 10.1 / 10.2
Final NDT tests shall be performed
Low alloy carbon steel 1(2) / 1(3) / 2(3) 1.2 / 11.1
when the part is below 50°C.
High strength steel
N.A. 2.1
thermomechanical
Martensitic stainless steel 6(4) 7.2 Final NDT tests shall be performed at
High strength steel least 48 hours after weld has cooled to
N.A. 3.1
quenched and tempered room temperature.

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8.2 DESTRUCTIVE TEST

It is requested to perform Hardness test measurement for the repair of martensitic stainless steel and high strength steel
quenched and tempered when a repair has been performed after final PWHT.

Material grade ASME GROUP n° EN GROUP n° With PWHT (HV10) Without PWHT (HV10)
Austenitic stainless steel 8(1) 8.1 N.A. N.A.
Duplex stainless steel 10H(1) 10.1 / 10.2 N.A. N.A.
Low alloy carbon steel 1(2) / 1(3) / 2(3) 1.2 / 11.1 320 380
High strength steel
N.A. 2.1 320 380
thermomechanical
Martensitic stainless steel 6(4) 7.2 360 400
High strength steel
N.A. 3.1 380 450
quenched and tempered

9 WELDING REPAIR PROCESS STEPS

9.1 CARTOGRAPHY REPORT

After volumetric testing, all the non-acceptable indications according to the specification shall be reported in a cartography sheet.
A template example in Appendix 1.

9.2 INDICATION REPORT ON THE PART

Control department shall report directly on the part all the non-acceptable indications with an appropriate tool (i.e. steel marker).
This marking has a color Yellow or Red which allow to symbolize the non-acceptable indication. Some examples are given in
Appendix 3.

NB : The method department and control department should define the position and side to perform the defect marking.

9.3 MARKING POSITION ON THE PART

Gouging operation may remove the marking of the defects. To avoid this kind of issue, the report of the marking need to be done
in BLUE color with steel marker at 150 mm aside from the original marking in yellow or red.

150 mmREPORT
REPORT OFmm
À 150 REAL
DE
INDICATION
L’INDICATION RÉELLE

INDICATION
REAL RÉELLE NOTÉE
INDICATION
PAR LE CONTRÔLE
150

Sum-up color
Defect indication detect by control Report of the indication at 150 mm
Steel marker RED or YELLOW Steel marker BLUE

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9.4 CARTOGRAPHY ANALYSIS BEFORE GOUGING OPERATIONS

Before performing any gouging operations, the operator shall analyze the cartography related to the gouging work. In case of
doubt, the operator shall discuss exchange with Control department.

9.5 PREHEATING CONDITION FOR GOUGING

A pre-heating is necessary before starting the gouging on raw material such as martensitic stainless steel and high strength steel
quenched and tempered (refer to associated Welding Process Specification).
9.6 EXCAVATION SHAPE AFTER GOUGING / GRINDING

A good excavation shape will lead to good conditions for the welding repair. All excavations need to respect following sketches:

D
Non conform indication

Le

45,0° 45,0°
D

• α: Opening angle of the excavation. It shall be at least 20° minimum. It can be more opened according to the
welding position.
• Le: Length of the start and stop excavation. The length Le is equal to the depth (D)
• D: Depth of the excavation
• R: The radius in the bottom of excavation need to be at least R=10 mm

R10

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9.7 CHECKING OF THE EXCAVATION DEPTH

After gouging, the depth of the excavation shall be checked according to the reference marking placed at 150 mm (previously
identified on the part).
This depth shall be conform to the cartography written by Control department. Otherwise, the gouging operation shall continue.
Checking of shape and depth can be done with a template.

9.8 GRINDING OF THE EXCAVATION

When the excavation depth is conform to the cartography, the grinding shall be performed before proceeding to the surface non-
destructive test.
The surface shall be grinded to white metal.

9.9 SURFACE NON-DESTRUCTIVE TEST

A surface non-destructive test is required after grinding. It shall be done by Control department.

9.10 TRACEABILITY OF EXCAVATIONS

Each excavation shall be reported in a traceability sheet (length, depth, width…). The template in Appendix 1 should be used to
help us.
This traceability sheet can be used by Method department in order to plan correctly the repair schedule with appropriate time
and volume.

9.11 REPAIR BY WELDING

When surface non-destructive test is acceptable, the welding operation shall be performed according to the welding book.

9.12 WELDING TRACEABILITY

All welding parameters should be recorded in the template given in Appendix 2. The frequency of records is at least 2 times per
work shift.

9.13 GRINDING REPAIRS

When grinding is to be applied (i.e.: hydraulic profile of runner), it shall be done with the respect of the dimensional tolerances
of the drawing.

9.14 NON DESTRUCTIVE TEST

NDT shall be performed according to the drawing and associated NDT procedure. A final report should be issued at the end to give
the status of the part.

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10 APPENDIX 1: TRACEABILITY EXCAVATION SHEET

An example is presented below with the minimum mandatory information which is required to perform the excavation
traceability sheet.

PROJECT EXCAVATION REPORT SHEET Repair sequence N°

UNIT WELD N° : / BLADE n° Before / After PWHT n°

W
45,0° 45,0°
R

D
D

CONTROL INFORMATION EXCAVATION METHOD EXCAVATION SHAPE EXCAVATION INFORMATION

Indication Dimensions CND report Gouging / Grinding / Preheating Radius (R in Width (W in Deep (D in Lenght (L in
NDT check after excavation Angle α (°) Date Operator Comments
reference Lenght Deep sheet n° Machining temperature mm) mm) mm) mm)

Data co ming fro m NDT carto graphy Defined by Co ntro l and Metho d department Filled by welding co o rdinato r / superviso r

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11 APPENDIX 2: WELDING TRACEABILITY REPAIR

An example is presented below with the minimum mandatory information which is required to perform the welding traceability
repair sheet.

PROJECT WELDING REPORT SHEET Repair sequence N°

Before / After PWHT
UNIT WELD N° : / BLADE n° n°
EXCAVATION PREHEATING INTERPASS GAZ FLOW RATE DURATION OF DISTANCE WELDING SPEED
WELDER DATE HOUR PROCESS BATCH NUMBER CURRENT (A) VOLTAGE (V) COMMENTS
REFERENCE TEMPERATURE TEMPERATURE (l/min) WELD (s) (cm) (cm/min)

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12 APPENDIX 3: EXAMPLES

Runner – Blade to crown / band – Indication in the root joint.

To report on the part:

Indication
Reportreport
à 150in mm
bleuen bleu

Length (LXX) and depth (DXX)

Noté sur la pièce

AUBE
BLADE
LXX / PXX
150

Indication in yellow
Indication en jaune

PLAFOND CEINTURE
CROWN orouBAND

Defect réel
Défaut dans
in the jointla
matière

This indication found in the root area of the joint was detected by ultrasonic probe, from the accessible side between blade
and crown / band.

The accessibility leads to have an excavation from the same side than the detection (in general it is an agreement between the
Control department and Method department).

Control department will locate :

• IN YELLOW: identification to the right of the defect
• In BLEU: marking at 150 mm on the blade to avoid to lose the visual marking

DXX will be the depth of the excavation to verify.

This kind of indication in the root area is a recurrent case, mainly due to a bad backside welding.

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Runner – Blade to crown / band – Indication in the base metal.

Indication
Report à 150 report
mm eninbleu
bleu at 150
mm

ToNoté
report
suron
la the part:
pièce
AUBE
BLADE
LXX / PXX
Length (LXX) and depth (DXX)
HXX
150

Indication
Indication in yellow
en jaune
X

PLAFOND
CROWNouorCEINTURE
BAND
H

Défaut
Defectréel dans
in the la
metal
matière

This indication found in the base metal (crown side in this case) can be detected by ultrasonic probe, from both side of the
blade.

Control / Quality department will locate :

• IN YELLOW : identification of the defect at the nearest surface
• In BLEU : marking at 150 mm is given according to the reference surface on the blade and no regarding the yellow
marking.

This kind of indication in the raw material, is in the most case, due to a brittle area in HAZ caused by welding.

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