ASME PCC-2-2008 {Revision of ASME PCC-2~2006) Repair of Pressure Equipment and PipingASME PCC-2-2008 OE iu aay el )) Repair of Pressure Equipment and Piping ® AN AMERICAN NATIONAL STANDARDowe ttn fl 7, 2009 This Standard wil be revised when the Society approves he issuance ofa new eon This Standare sis become elective & months after the Date of susnce, There wil be no addends esd t ie ‘dion, ASME issues witten replies to inquires conceming interpretations of technical aspects ofthis document interpretations are published on the ASME Web site under the Commitee Pages at pel fstootsasmeorg 35 trey are issued. SE the pine deat of he Amen Sco Maca Eges 1s cote sda was eloped uncer pds eda meen the te Aman Naa Ssanansne Sanes ommioe atop he deo ana we dt ct a ca om {opted comermed tka hd en apeiy partite The pope ede wan ar ae "ste cee nena apes pry ail pabiclepattom ni em, ‘pn cence n te t a Tv es et “approve” teen” ye. cote, ppt dee, hy. ‘Su ae at a ay poston wt eset oh ol fy pte pasar in omen may tena mene ni een dns nt nce 9 ayer Wig 2 ands git ay Ingen rcpt ts ate ease oy sch say, Un eae raters re ‘edt drain oe vate ny such pet ns ane ek ingame uch a trey tn eps. tpt by ee anc pena of paso) aed wi int ot 9 Be tp erremest ony ends of Os cote Sad. ASME bts respons ny aerate hs comet ed insane mth ewes ‘sv ross pale ih ees the Seance entrants by aon pr fis doumet mayb produces i fom, it! orien pron oe pate cco ait tecnica Eines "HE AUER SN oF ESTA. NINERS ‘rms nSForeword CONTENTS reparation of Technical Ingen ‘Commitee Roster ‘Summary of Changes Part ant 2 Adie 22 Alice 22 Atco 23, Ace 24 Ace 25 Article 26 ‘nice 27 ‘ance 28 ‘aril 29 ‘ance 210, Ac 211 ‘avle 212 ‘rise 219, Pats Acie. Ace 32 ‘cle 33 Acie 34 Ac 35, ile 36 Acie 38 Alice 29 Ace 320, Ace 331 Alice 312 Pat & Atle 41 ticle 12 Astle 43 Pa 5 Arce 6 ‘ice 52 ‘Scope, Organization, and Intent. Welded Repairs ‘Dat Welded Insert Pises in Pressure Components Exlemal Weld Overy Rep Ineral Thinning, Sea eded Threaded Connteion and Seal Wel Reps ‘Welded Leak Bor Repsir ‘Welded Lip Seals (nthe course of preparation)... Fall Encirement Sta Reinforcing Sleeves far Piping Filet Welded Patches With Reinforcing Pi, Welds Alternatives to Tadional Welding Preheat ‘Alternatives Potweld Heat Trent Invdervice Welding Onto Carbo Stel Pressure Components of Pipelines Weld Wutldup, Wild Overy and Clad Restoration Filet Weldad Pater “Throndd or Welded Pg Repair Mechanical epais... o Replacement of Pesute Components Freeze Pgs “Threads in Tapped Holes hw Bacavation and Weld Repair Flange Repair and Conversion Mechanical Clamp Repair Pipe Stghteing or Aligent Badin Damaged Anchors in Concrete (Pstinstalled Mechanical Anchor) « Valves With Pressure Seal Type Bonnets (nthe course of preparation) Hot Boling inthe course of preparation) Hot and Hall Boling Removal Procedures Inspection and Repair of Shell and Tbe Heat Bxchangers 0... Nonmetaic and Bonded Reps "Nonmtalic Composite Repair Syste or Pipelines and Pipework High Risk Appications = - [Nonticalie Compost Repair Syste for Pipelines and Pipewodi Low-Risk Apiatons [Nonmetallic Intemal Lining fr Pipe: Sprayed Form fo Buried Pipe Examination and Testing Premture and Tightnes Tsing of Piping and Equipment [Nondestructive Examination in Liew of Pressure Testing for Repairs ‘and Alterations 1st 4 186FOREWORD ASME formed an Ad Hoc Tk Group on Pot Coat in 1993 in pons tan nad vee or eogrnn an generally spies engineering wanda forthe opection a one ‘ance of pressure equipment fei fs bon ple! in seve A the ecomwrtondation os “ask Group, the Dard on PrsureTeaogy Codes an Stats QPTCS) formed the Fst. Crateton Commitee (Uc) n 90. Inestped! hisconmitee wnat deveop and maine Standard addresing common trues and Wchsogke ltd to post-conetracton active snd to work wth other conse commits nthe developmen of sopra, prdcrapecie cates {nd wandards sodising tues enone cher nal oetcton fo upet and pg ‘over by Praaue Tecnology Codes and Standas The BPTCS coves nonce Des, fete tac cans Roe cage) ng nd ping ong pan, Sore SHE RCC sles tran ob developed based on Mei nee nd the aay of solunters. The FCC formed the Subcommitce on inpection Pinning andthe Sucommtoe tn Fae Evolutions in 95, n 1988, «Tsk Croup Under the FCC began prepacing Cubes {tr Pressure Ooundary Bled ange ot Assen In 199, the PCC foed he Scone Repair ant esting In 20 he Sabon on Haw Evluton ws dasled and paced ty the Joo ASME/PI Commie on Fitness for Seve Other topics ae under cnaraton fd may be developed ino ute gue documents “tne ecommites were changed with preparing anda dealing with several aspect of be inate epeton andl wadtcancs of prs paper piping Ts lepectioe Psring Sondnnd pve gunince onthe preperation oft sched iepeton pl Deets tte ‘Seiied ve hen vals, when appropri, sg he procedure Proved te Pree for service aly its determined tht rep are egued, guidance on rept procedues fs provided in ts Repair of Presa Equoment snd Piping onde. These dosent se a ‘eros tg of prepare ‘None ofthese doctment are Code. Thy prove tsrgned and generally accept good practices tata be usd in conjanction wit st Constuchen Cds suchas APLSIO APES, [nd NBD, and with jossconl seulement "he fist eon of ASME PCC, Guns or rs our Sli Flange at Asn wer approed for publi 20 ASMEPCE 2 was approved the Aen tonal “Sie ati (ANG) aan Arc National tndan! on Nove 52000 “he ist dion of ASMIS PCC2 Rui of Prosar Euimetend Piping, wan approved for publication n 200, This wisn was approved by ANSI aan Aran Nal Sedan Sepembor 25, 208PREPARATION OF TECHNICAL INQUIRIES. trRopUCTION “The ASME Reet Construction Standards Comite il consider vitor request fo inespre- latons and revisions ofthe rule ofthis Standerd and develop new rule if ica by techno {il develapment. Ths Commit’ activites hs eg are limited sity to interpretations ofthe rules orto th consideration of revisions t the poset rus on the Psi of new data ce {echsology Asa mater of publshed polcy, ASME docs not “approve,” “ceri” “rate” or “endorse” any item, constriction, propaetary dove, of activity, and accordingly, inultes ‘requiring such consideration willbe retumed, Meroover, ASME does et act as constant on ‘Specific engineering problens or on te general application or understanding of the ules [sed the inguitytnormation submited, the opinion ofthe Commitee thatthe inguirer should seek profesional ausistonc, the inguiy il be setumed withthe recornendalon Dat Sich asstance be obtained “Ainguiry tat doesnt provi the information needed for he Committee’ fll understanding wil be rtm. REQUIREMENTS Inquires shall be lined strictly to Interpretations of the rules orto the consideration of sevitons tothe pent eles cn the basis of new data or technology. Inquiries shall most the following requirement: (a) Sap. Invalveasingl ul or closely related rules inthe scope of the standard. An inquiry Inte concerning unrelated subject wil be retuned (}) ekg. State ho purpose o henge, which maybe either to aban an interpretation cof rl of this Stand, ort propose consideration of sevison to the present rules, Provide ovcnely the information needed forthe Committers understanding ofthe inquiry, being sure to include reference to the applicable Fat, Artic ition, Addenda, paragraphs, figures, nd {ables If sketches are provided, they shal be limited t the cope ofthe iy (6) Inquiry Srctre (0) Propuced Question). The ingir shall be stated in condensed and prcse question for smal omitingsupedluous background information, and, where appropiate compesed in such 1 ay that "yes" or “no” (perhaps with provisos) would be an acceptable reply. The ingly Staloment shoud be technically sd editorially cores, (@) Praysed Reply). Provide a proposed reply stating what te inquirer believes that the standard requires Fin the ingulzer’s opinion a ovision tothe standard i need, recommended wording shall ‘be provided in alten to information jstifying the change. SUBMITTAL Ings shall be submited in ypewriten form; However, lege handweteninguees will be considered. They shall ince the name and mailing address of the inguer and may ether ‘be sent by ema to SeestaryPCC aeme org or by malt the following addres: Secetany [ASME Post Construction “Three Patk Avene [Naw York, NY 100163550,ASME PRESSURE TECHNOLOGY POST CONSTRUCTION COMMITTEE The lining se ste efthe Canine the in opal the Standard) ‘STANDARDS COMMITTEE OFFICERS Shot Seman STANDARDS COMRITTEE PERSONNEL Fest The Sn chm ents, cnsatan on ‘mor Madan Engrese ‘ol | ies cst Weber, hy fea Gace Ta ashore oo of aes ese Wesel eels, consaat oes Set Gta! Sesn US, tASME PCC-2-2008 SUMMARY OF CHANGES Following approval by the ASME Post Constiction Commitee and ASME, and after public vies, ASME PCC-2-200 was approved by the American National Sandards Institute on Septemooe 25, 208 ASME FCC2-200 includes eitoril changes, revision, and coeetins introduce in ASME PCC2- 2006, a8 wll as the fllowing changes identified by margin not, (5) Page Levan Change 2 ‘Tble 1 Revised 0 Ate 22 “Tie revised a nice 27 Ades a Artiste 28 Added 2 Artie 29 Added 6 Artie 210 Added a Ace 211 Added e Ace 212 Added 6 Ate 213 ‘Added ” Anicle 32 (2) Paragraph 27 deleted and pars. 28, ‘heough 210 redesignated as 27 through 29, respectively (2) Paragraph 31 re i ts entry oT Aisle 33 References i section 7 updated as ‘Auicle 3, Mandatory (1) In para. Ib. nowendlature for Sy ‘Appendix I coreted 0 tend 3Ay by erat (2) pura 1412, ASME BL oferenc in Note pata (6) Tite of pra HH1.21 revised 1,95 Aussies (0) Paragraph 22 revised (2) Paragraph 3 reve 1 Rap 2 eee () Nevepamn added us. Aut 311 Added 9 ancl 312 ade rae Article 1 (2) Tide revised {@) nL, subpara, (ade (6) Paragraph 21 ft revised (In 31 Fay added (6) In 333, supra.) added {6) In 242, las paragraph revised and new og (I) and (2) added (OV Mabe 2 ite weve180 156 7 156 161-16 19 ‘Aticte 41, Mandatory ‘Append ‘Article 4.1, Mandatory ‘Appendix I Article 41, Mandatory Appendix V ‘Ail 4.1, Mandatory “Appendix VIL ‘Act 41, Mandatory ‘Appendix Vit Ate 41, Mandatory ‘Appendix Be Article 42 Atle 42, Mandatory “Appendix Change (8) In 3.43, shah pargeaph revised (9) Tables 4 through 7 rodenignated as “Tubles 3 dheough 6 respectively, and previous Table 3 deleted (40) in 345, ost paragraph revised (1) in 53, fist paragraph revised In 13, subpara. (6) added In 2, second and thed paragraphs vied! (2) In 24, naw dhe paragraph added () New eq, (V2) addet In Vint net sentence of fret paragraph revised (In VIS, subpar.) revised (2) In VIIA Brat tee paragraphs revised (9) In VIS, sbpor. (92) revised in, erm dsbondmont added (0) Tite revise (2) Paragraph 11 reve ints emiaty (9) Parograph 12 revised in is enety (4) in 14 st sertnce revised (5) Paragoph 21 ie vised (6) Paragraph 22 tie revised (7) Paragraph 24 rvs0d (@) In, definition for d revised: symbol E corrected to rad Ey and definitions oy leg Sg a ed apap 33 revised in te entity (G0) Paragraph 33 revised ints entity (01) Paragraph 3 revised ini entity (02) Table rovised| (03) Tle 2 under Materials ‘repavaton, “esa” replcs with polymer" (19 Paragraph 4.1 eevse in entity (22) Pasogtph 43 seve ini ty (6) Paragraph 51 seve init erty (G7) Paragraph 52 revised in its entity (a8) Section 6 revise in sentir (05) Table 3 entry foe Interface ‘vied all references tein” replaced with polymer” (20) References in seton 7 updated (1) Porageaple 1 rove in its eticty (2) stp ae (@) Paragraph 113 revise ints entirety7 im m rs m4 19 15, 186 Lacan Article 42, Mandatory “Appendix I Article 42, Mandatory “Appendix TY Arce 42, Mandatory “Appendix V utile 42, Mandatory “Appendix VI Astle 4 ‘Article 43, Mandatory ‘Appendix It Article 43, Mandatory ‘Append It Aisle 51 Artie 52 Change (2) Paragraph 0-1 revisd in its entirety (2) Paragraph I-2 revised in its entirety 2) Paragraph 1V- rvisd in its entity (@) Paragraph 123 roviod ins entry 2) Paragraph V1 revisits entity {@ Paragraph V2 revised in its nity {@) In para. V0) term “resin” replaced (4) Paragraph Ve reviced ints entity (6) Perageaph VOID) revised (2) In VEL, term stoner! added (2) Definitions for ardor aed i rerized (6) Term resin ost revised to rend al syste (4 Term thermo! ests revised wad thera plymer Revised in it entity Revised ints entity (0) In et, definitions for eet nae Pie (CBD), curing, eps, paraded non and reno rc (2) Angin term polyer added and terms resin filer ae thermoset peste revised to read pol ler and Thermos palmer respectively (6) Panag IF? updated Revisd in its entirety AddedINTENTIONALLY LEFT BLANK.‘STANDARD FOR THE REPAIR OF PRESSURE EQUIPMENT AND PIPING PART 1 SCOPE, ORGANIZATION, AND INTENT 1 SCoPE ‘This Standard provides methods for prof equip rent and piping within the scape of ASME Presare Technology Codes and Standards after it has been placed inservice, These eplr methods incude relevant ‘lesign,fbvcation, examination, and testing practices did may be temporary or permanent, depending the “he methods provided in this Standard ade the repair of components when repairs dered necessary based on appropriate inspection and flaw assesment ‘These Inspection and Aw evaluation methods ae not ‘covered in tis docurnont, but are covered in othe post “onstruction codes and stndacds ‘Only teencal procedures a information are pro- ‘vided dminstrativeor policy requirements ate outside ofthe scope of this Standard 2 ORGANIZATION “This Standard is dived int ive Fars. (a) Pat 1 covers the sope, organization, and intent snd ie applicable oll articles in this Standard. Tae [provider glance forthe applicability of repair met ‘lise inthis Standard 1) Pat 2 covers repair methods and techrigues that include the use of welding, beazing, soldering or other ‘ethos vowing metal epost 1) art 3 covers mechanical repr, with o without sealant such as bolted camp or fixtures and includes All epaie methods not covered in Patt 2 Pat & (Par 4 covers repairs using nonmetallic means, suchas nonmetal ies and wraps andbonding Joining by epoxy), including bonding of metallic component, “Tipe ant piping within the op of AE Pcs salen Cade alot sina Protege Suskomsssaser {) Par 5 covers examination and testing methods and techniques, 3. TENT 3A General ‘This Standard provides technical information, proce: ues, and recommendations for repae metiods that ‘were determined by consensus fo Be recognized and generally accepted good engineering practice, Where [Ssuipment repair abject to jrcictnal epulation, Faredicionl approvats may be requied. 32 Definitions ‘The word uy sland sould are usd in the repair. nics of PCC2 and they have the following intent may: indicates an action that is permitted, but not requires Stal a ation thats mandatory Iindcates an ation that i am escent element ofthe repair method that ‘not be eliminate shoul am action that snot mandatory: tinct an Action that wien performed fs generally considered ‘Degood practic however, there are some circumstances ‘when the action i not appropriate or require, so the ‘ver abroadrangeacrcumetances It isnot enaadatory Unless 5 specie by oer inthe apllation of those ances 3.3 Administrative Requirements For administrative Aiton equtements Inthe abeence of an applicable ppst-costructon code or jurisdictional requirements, {he owner ofthe pressure aquipreat oe piping should‘onbjoupaL Hedy 19 VORDe.OS OMY 10} epINg FmITEL‘R6 spoaau soo Me au yrs (1063) nb apa] dey yo WONDERS Bh Ha} PRD TRLestablish the tive requirements. A post ‘onstruction code sone that provides reqlrements and {uldance for inspection and/or repair of equipment ler it as boen placed inservice, and may inca the ‘eferenoes to oxgnal code of consul, Fsamples of postconstriction codes include NB-23, API 510, ‘APL S70, and API eS 3.4 Application ‘Users ofthe artces contain! in this document ae seuione that ene arttenhavs been developed yee ically and are recommended for general applications ‘Thay may not necessarily be stable forall apliations. Procautionary considerations are provided, but shoal note considered all nusive. Sound engncerng prac ties and Jadgisnt should be ased to determine the applcailty oF a specie method or part of 8 method {Oe specie application. Each repair ould be subj. {0 an appropriate review By qualifed personnel, and {his eve should consider subsequent deterianatin of the mpaied component ‘Some limitations and considerations ar contained in ‘section 2 ofthe individual ates, 35 Alternative Use ‘While thisStansard covers epi equipment within the scope of ASME Pressure Technology Codes and ‘Standart may be used on equipment constructed in sccordance with otber Codes and Standards. 3.6 Ailes independence Individual articles in hi Stand ay be use inde- pendently of other articles, except when othervise ote. However, this Part Patt) applies to all aries inthis Standard 3.7 Repair Life [any of the repair techniques included inthis Standard are considered tobe permanant, intended to remain in place forthe ie ofthe repaled component (ters may nly be stale for short-term serie, ana ‘should be replaced with a toee permanent repair af the appropriate opportunity. The anticipated life of the repair dapends on many ciecametances, and could Time coxsidortt of sk A acy this Seanad oes not las repair methosas permanent tempo rary. Rather, technical considerations that affect the expected life of the spi are stated inthe individual tls 5.8 Code References Reference to specific cad generally avoided inthis Standard because the equipment or piping could have been consrced in accordance wth numberof lifer entcadex Where sacha references proved, tl anes ally the intent to include, by reference, a spectiie fechas! provision 39 Welding Rayucement for welding inleding salifstion of welding proce, weld, and welding opto, ‘ould general fw an appeablcose of constue ten or an sppeableposteontrction code, cept ‘whan eters speed hore 3.10 Allowable Sess Calculations involving the allowable stess ase the allowable stress from the original code construct 'n applicable post-constuction code, unless etherwise Speciod In speci ties. 3:11 Examination When qualifications of examiners, methods of xan ‘ation, extent of examination, and acceptance erin se not spect, they should follow the equicemns: fof an appliable code of entructon or an applicable pastconstucton code 3.12 Records ‘The owaee should keep records thal document the repole Specific equrement for documentation se not provided in th Standard The owner shuld eta oe ‘rds that comply with applicable jurisdictional and ‘ost construction code requirements. Documentation tray include such toms a a description ofthe condition that required attention and it ate, repair procedures ‘at were used, Poles prior tO and after the repair, ‘raminaton procedures and eco, eat eaten bets, test veces andthe ramen of the persons rms peeloeming the rpairand examination an thelr cet Eatin. The dacomentation form part of the history of the prsure component and shouldbe etalned as ng asit is elevanePART 2 WELDED REPAIRS Article 2.4 Butt-Welded Insert Plates in Pressure Components 1. DEScRIPMON 1.4 General Considerations ‘The repair of prssure components by buttewsled insert plates involves the replacement of pressure [outlay material im» presse componcet with an incr pate attached by fl penetration but welds. Ths ‘pale method applicable a cylinvea sphere and ‘oni shells and to flat pressure components. I ay be used for single and double curvature shall It may tlio be ved on ober prea comnpenenta (ch at forme beads) ifthe curvature of the replaced section rmotches the curvature of the original pressure part. 1 Sat limited by the si of the prenare compenent cept where practical considerations preade the ee fan srt uch a sal mee eo ab. ‘may be sed on small diameter presse component {Pec veo lun to eure & cue ft oe et Plate an the existing pressure component and thatthe fepaired pressure component ines the tolerance requiroments of the applicable code of construction. 1.2 Replacement of Local Areas in Pressure Vessel ‘Shells or Pipe Walls ‘This repeie method is ntended tobe wed to place portions ot pressirereaining vessel sbi pipe ale that have bun damaged by cracks, local wal: hing ‘rom erosion, corrosion, and ether damage mechanisms ‘The insert plate may contain one or more nazzles/ mana 1.3 Replacement of Entire Component Replacement ofan entire component shel plate oF & complete shell course of acylindsal sel ors compte tirealar segment of «sphere, or a complete head, oF 2 Section afa pipe not considered inthis repair mets 2 uMITaTIONS: 2. Patt tof This Standard Pact of ths Stondand contains ational require rants nd iniations. Thi Artic hal Bouse con junction with Part I. 12.2 Additional Considerations and Limitations ‘When applying this repair method, consideration shall be given to compatibiiy of materials, operating, ‘conditions forthe inended life of the componan tin, fd welding to minimize the residual steses and di" tortion, and any limitations on nondestructive exam ration and pressure testing. 23 loadings ‘The method may be use for equipment subject to “thr internal or extemal press Ifthe presse com Ppnentis subject oextema pressure adltonal ons {ration shall asa be given to any Toss of buckling Strength asa eh of permanen! disrtionsor misalign: tent inthe pate eorsponent I he recurs compo ret subject io yclilouing eitonaleonsderstion hall be gen othe effec of permanent distortions on ‘he fag le ofthe repaired component. 24 Comosion-esistant Weld Overlay or Cladding ‘This rate method may also be wed in vescls that ae ether clad with conesion estan! lng oe Weld ‘very. The inser plate cladding ot weld overlay shall, Iecompatile wih the existing maton nd suitable for the intended service. Consideration shall also be sien othe ue of weld details and welding predures [Stabe for the intended service 25 Dissiniiar Metals Use of distnlar materials (ase mata and we) not protbied, but the nate all mt the raid Inti nehanical properics forthe presure com ‘ponent and shal becarealyevluated forcompasblty[betwen the dissimilar mitral and the sevice en = ronment, both iforal aa external thermal age isapossily, consideration shal be given tthe pote til for aceerated fatigue cracking in the disse seta combinatn, 3 DESIGN 23.1 Code of Construction “Tho incr pate tikes. materia welds shall moot the dsignregurements i the pplicable code of “onsuction forthe existing pressure component into ‘whlch it bing iste and shall be consitnt with the joint ficiency oe joint quality faces used in the ‘orginal design, exept ae permite in para 33. The llsable stresses sl be the sameas inthe applicable ‘ode of construction fr tho ewsting component 3.2 Materials Insert plates nd weld shouldbe of the same materia asthe existing pressure component or of anther mate- Fil shathasat east oqual etch toughness and aloe ‘rer, conforms tothe of the applicable ‘code of construction, and is suitable for the tne Suvice. Where ASME materials are used, the place ‘ent mates shoul have the same ASME P-Namiber 13 nm (i), the greater of 250 mm ADin) and where Ty thickness ofthe thickorf the two adjacent butt wel, mm in) 4.3.2 Alternative Spacing Between Won-Postweld eat Treated Butt Welds. ‘Thespocing between adjacent ‘ompostweld heres carbon and lew alloy see ute wels may be reduced othe ser of oF 20mm (Gin) for tgs 40mm (0's), provided both but welds fare ground smooth, 100% RT ge UT examined and 100% MT or PT examined aftr completion of welding Inatoas where the spacing teteen the adjcent butt ‘Wel Tes than that specified in pa 42.1 As an “Ulernative, the oot pas and the wel ater fai of he {roovets ied, maybe ether 100% Mor PT cxarined {place ofthe 100% RT or UT examination raqlrement ‘hve. The bat welds with theknesses less than 3mm (fin) need only be MT or PT examined. See para. 5 4.3.3 Spacing Betwen Stess- Relieved But Weis. ‘Te spacing between the adjacent bt welds shall be ot fess than 2 if the fst but wed ts ren ses relieved before making the second but wed 2g etc te oct ‘44 Inerseting Butt Welds in Carbon and Low Alloy Stee Pressure Components ‘44:1 General Considerations. Inerseting insert platen existing bt welds shouldbe avoided where possible Where it impracil for the facet plates to ‘voi an exiting nonetese relive but weld the inert pte but eld shouldbe placed sch tat eters {he exting but wold a an ange not ew than 30 de, fs shown in ig 2 Alternatively the insect plate may the aiand uch that i inerent he esting bat wok 3 50 deg angle as shown in Big, ‘44.2 Examination, Unless 107% RT or UT examina: on i reguied by th appliabe code of constuction, ‘he inser pate Butt weld and 100-mm (Ln) oF the ‘isting bat weld, on both sides of the intersection, Shall be 100% MT oe PT examined afer completion of both welds ar shown in Fg 2 Incase of the"doghouse” {ype inert pte but weld shovenin 5 his examina thon shall Be performed! en he fal length of te new weld along te exiting shel but joint. See para. 5 45 Postweld Heat Treatment 4.5.1 General Considerations. ‘The butt welds boven the insert pte an he existing pressure com ponent and the weld Between the nozre/manway ad the ner plat shal be posteld eat teste (PWT) when required by the egal code of construction ‘heapplieate post constuction code, or for proces ret sons, except a5. permitted by the applicable postconetrction code. Proper precaution shoul be {Eken during the PHT to avoid distortion ofthe welded assembly 45.2 Repairs. Repairs to pressure equipmont that require PWIET based on serve conditions shall be ost ‘weld hea ated, ules other neans (eg, engineering ‘valsaon) are provided fo ensure tat the a-welded Joints will be ntable forthe sevice conditions, oF as Permited by the appiable postconsiucio code ‘AS PWHT. or the repair pressure ports that require PWHT (ether Code-mandated or dependent upon service coniitions), the PWHT shale performed In accordance with the applicable code of construction, teas the er euler PRT Ce Nghe PWT temperature or longer hl ie). 5 EXAMINATION OF WeLDS S.A Insert Plate Welds All inser plate wold to he existing pressure compo- ‘ont in pressure vessels shall be examined by radior ‘eaphle RT) o ultras (07 xarnation methods to {he extent required bythe applicable code of construc tion oe postconaraction cage forthe presse compo: nent: Where UT i wed, examination of the rot assbyeithe magnetic particle (MT or guid-peneteant (1) methods is recommended. The procedures, personne ‘qualifications and acceptance entra shal bein secon ance with the appliabe code of construction or the palcable postconstraction code 5.2 Finished Welded Surtaces Unless 100% RT or UF examination is ree, finished welded sustacesshallbe examined by magnetic particle MI) or iguid-pontrant (PT) method. Esa ation bythe MT or PT methods ic ecormnde for the woot pass of sngle-grove welded for the Bac gouge of double groove welds No crcklke indica tons, incomplete fusion, or incomplete penctation ae permisable 53 Piping For piping ll nondestructive examination seguir ments thal be in accordance with the caret equi iments In the applicable code of construction oF Postconstrsction code 5.4 Additional Examination Requirements fr Carbon And Low Alloy Steels 5.4.1 Rectangular and Square insert Plates. Fos rectangular or square inset plates, the welds around the rounded comers asa minimom, shale ele pot Rf or UT examined, As an allernative, he toot pat the wel afer al ofthe groove filled andthe coat pleted weld shal be ether NT or PF examine, 5.8.2 Closely Spaced and intersecting Welds. Soe paras 3 and 44 Tor additonal examination equi ‘ents for closely spaced welds ad intersecting welds 6 PRESSURE TESTING 46.41 Gonera Considerations 1 the veel ox pipe canbe salated for pressure test sng, and ft practical todo so al set pate welds 0 shouldbe pressure tested as requlted inthe applicable Postconsitucion code. Alternatively, nondestrictive ‘tamination may be performed in place of pressure est ing permittedby theappllable post-censtraction code atthelocatonofthepesure equipment when cont nation f the pressre-etaining ite by igus s pos blo or whan prssue testing not practi. {6.2 Notch Toughness Considerations 4 Conseration shold hg th fat see vice deterioration and embrilement from pri service Eonditions on notch toughness characteristics of he pressur eomponentbofoe pressure testing Teper helshall maintain safe distance rom the press com ponent when the pressure is incensed fort fist Ue, (b) Additional safety precautions shall be taken in case of a pneumatic lett rae the sk of Bite ‘actor (@) Considerationshould alsobepiventoany hazards that might be associaerd withthe est medium Wout, fannability, xplsivenass, ee) 6.3 teak Test A separate leak est (sua, bubble forming solutions, ‘site etc) may be deszable to check for leaks before pressurizing the component othe maxim tt press Se. Such ak test should be performed st 2 sake pressure that substantially les than the axiom fest pressure by pressurizing the component toa desied pressure and reducing the peessure othe lak tot ree Sure Beloreportorenng he lok test 64 Vessels and Piping With Insulation or Coating Alltesting an inspections shouldbe performed prior to apliciton of insltion or costings,Article 2.2 External Weld Overlay to Repair Internal Thinning 1 DescRienion 1.4 Introduction "This Article address the repair of pressure compo ens (piping or pressure vessels degraded by wall hin ‘ing de to low acserated corso (FAC) erosion omeson (EC) and other interna thinning mechanisms by overlay of wold metal on the exterior a the deraded pipe or pressure veal ston. This Aetisle docs not dros the epi af eracked component. 112 Restoration of Wall Thickness ‘When appropriate, appying a weld overay repair to the exterior of thinning pressure component (pipe pressure vessel) can provide the necessary strututal Feinforcement and caneliinate the nes for ether ttl ‘eplacernerdof the component or an intemal welt ep Spociealy,o weld oveay procedure can be used 10 structaraly restore seal arbor, low alloy or austenitic sinlns ste mater sua or welded contrac: n}componentstothe appropriate wall thickness with tout resorting to replacement efor In some cases its possible fo perform a pate wile the component iin ‘peraton. The ee of ed overlay ae 9 permanent ‘pa shall Include consideration ofthe thinning techn, 2 UMITATIONS 2.1 Additional Requirements Pact 1 ofthis Standard conttine addtional requis rent an! tains This Artie shall Be wed in co junction vith Par 22 Cracking ‘A weld overlay shall not be used for strctual rein: forcement whea there i indication of any form of cnsking. 23 valuation of Medium In all cates the ser shal vakuate the family, oti, ard potential reactions of the medio within thepresure component eorto application ofany weld Ing poses In no case should weting be performed witout e thorough understanding ofthe medium con {ained within the pressure component Ths should also Include an evaluation ofthe medium for potent ea tds wth the bse mata eto the heat rom weld ing Bsamples of procene media tt shoul be properly Fig. 1 Weld Overlay Profile Lea SRS L = ‘shed For the aystem por to repli includehydo= envhydrogen cyanide, oxygen alkaline /eaustc mater 1s butadiene, acetylenic compounds, HS, coin, and fein some cases, earn proces maybe ncces ‘Sry t prepares pesne component sytem for ep 2.8 Operation in Creep Temperature Range Overay epaes of components that are operated at ‘or near the ecep tomperatere range should only be {qualified theough an engineered design approach 36 ‘described in section 3 ofthis Arte 2.5 Blockedin Liquid Filed Components ‘locked-in MygukeMed comport sould ot be repaired due to dhe poeta for pressure cess rom ‘ermal expansion. 3 DESIGN ‘gare 1 depts the weld overly dimensions refered soim ths sation 3.1 Overlay Design ‘The weld overlay shall meet he requirements of paras 3 tough 9222,3.4.1 Weld Metal 3.4.3.1 Chemistry. The nominal chemistry ofthe deposited wold metal shall match the base materia 3.1.12 Tensile Strength. The tensile strength of ‘he deposited weld metal shall bea eos 100 ‘exceed the tensile strength of he base mata Which the weld vecay is applied 33.13 Altratve Filer Metals. Alematve ier metals (0 those specified above) may be used with SPoroprate design calculations an nes or see ‘raluatons. 3.41.2 Overlay Geometry Genera Requirements 3.4.24 Postrepair Examination. ‘The design ofthe overlay shall not hinder pastepate examinations an ‘valuations or any peesertce examinations 3.1.2.2 Extension Beyond Base Metal. The weld shall extend, at fal thickness 2 minimum distance i ‘ach direction beyond the ast base mal sles ‘therwie jst By a fines for service asessmen). 2 cuter radius ofthe component oD ‘ominal wall thickness ofthe component 3.1.2.3 EageTaper. The edges ofthe wold oveday “shall be tapered to the existing presture component su face ata maximum angle, «of #5 deg 3.24 Life of Repair. The thickness shal bo suth- ont to maintain dhe predicted fe ofthe pit. 3.41.25 Comer Radius. All comers ofthe overlay shall ves ras not es than the overlay tikes 3.4.26 Corrosion Alowance. Aay cerrsionallow ‘over the design ile ofthe restoration shall be analyze 3:27 Spacing. Inaddiion,twoormoreovedays stall not be spaced any close than %/Rljg, Between We tow of enck oer 3.4.2.8 Thikness. The thickness of thecompleted vera dimension win Fig shall atexcod the non fa chase af the presse component 3.4.2.9 Other Configurations. Configurations not smectng the rqrements of paras 31.1 and 31.2 shal bbe evaluated. based on’ engineering, analysis (para. 31.32) 0 testing (pera. 31.3). 3.4.3 Overlay Qualiieation Requirements. Tae design of the weld overlay shall meet one ofthe {etlowing {@) guidelines for prequsifed design in para. 1.31 (@) guidelines fr englosred design in pra, 31.32 (6) aidelines for proof (ourst test in para 3133 3.43.4 Prequlifeé Design. Applicaton of weld ‘overlays on straight piping sections and associated wold To correct mite degradation may be corsiered 4 propa Wdasgn and shall be exempt trom an eng ‘narod design qualieation oe «proof est qualification Ital ofthe flowing conditions sre met fa) All ofthe recuvements of paras 3.1.1 and 312 (0) The maximum design temperature does not exceed 440°C (507, (Tho spaced nominal thickness of the exiting nse tals at leat Schedale 40 or Stand Wall whichever ses, (@) The maximum angle ofthe taper does nat exceed 30 deg (ain i (© The finished overay i relay, oval, fll eeu ferenal, o rectangular in shape {f)Foreach cpa the maximumimension( length alongaxis)eompensatd by a eel oar ean lar overly does not enced the Ieee of oneal the ‘minal ouside diameter ofthe pressure component or 200 mm im @) Rectangular overlays are aligned paral with or perpendicalar to the ais ofthe presse component, Sd comers are rounded! with radi not ke tha he (veraythicknee iy Oval overlays shall have end adi not les than Y Rpg a0 the axis ofthe overay shall be aligned parallel with or perpendicular tothe axis of the ‘Somaponent {) The slnimum thickrass of the overlay shall be sulfcet to resto the nominal wall tikes of the presoure component. This canbe accomplished by stib= {eating the emai thiknese rom the nominal ck ress ofthe component 19 abtsn the ried overlay ‘Nekaess () The thickness of the overlay shallbereatvey uni form except forthe tapered edges. ‘If Meaty analysis was require by the eeiginal ode of construction the fet of the weld overay shall Fe voenneii withthe eigal age or auld accordance with pare 132. 3.3.2 Engineered Design. The weld overlay may be gual by an enginoad desi. The allowable test ‘vals of thease metal shall apply tothe design of the vol metal and the following factors shale considered Inthe design: (a) the fects of thee-dimensional shrinkage (the elects offen, stress concentration, ard section propertos () stessconcentaton rom the prssurecomponent fnteral surtace configuration(the oft of dering thermal expansion cof- ants betieen the base and the weld metal {othe fects of difering thermal mas ofthe overay repair i) the potential for cep degradation or sevie te perauree above HO" (680%) 3.43.3 Proof est Qualieation. Asan alternative tothe prequalified design ov enginered design a prof text quaifaion maybe performed tough astiactory burnt text maccup. The details ofthe mock-up contig Tallon and considerate ae in pan 3 3.2 Burat Test Procedures 3.2.1 Proof Test Qualification Requirements. Asan lterative tothe engined design approach burst est ‘of a mock-up overlay may be perf f qualify 2 ‘veld overlay design. 3.2.1.1 General Requirements. satisactory mockup burst test may be ted tua the weld ‘veray design for applation in the ame orientation fm the same typeof item, ane the same location ting, when te fllowing conditions ae met (a) The base metal sof the sme P-NO. and Group number as the mock up bass material este (0) The specified minimum tral strength of the tem doesnot exe that ofthe mock-up base mater. vested (©) The average thickness ofthe overlay areas i at least the thickness ofthe mock-up pl in Fg 1 {i The oveap on the full thickness of tase metal, 2 is at eas that ofthe mock-up. (©) The tansitonangeat the outer ages of the over lay a snot greater than that ofthe mock-up. {f) The overlay sures sine o oe smoother than that tasted ig) The maximum aio dimension/dameter ratio, 1D, not more than that tested {) The maximum cigcumferential dlmension/ ameter rato, CD, is not mare Ban a ested {0 Tho nominal diameter isnot ss than one-half more than 2 ties the ditnter of mack lest {Tho nominal thickness /dlamter rato 1D, not vot than anhalt 9 Hos th ral tes. 32.1.2 Simultion of Thin Area, To smite the ero of walling fr pressure testing, a rounded Eomersagmentofthe base material ofthe mock-up shal be romoved to represen the maximum size ata (2a ‘limenson of aed etcursferental dimension of) and location of thinning o iting tobe compensated for by the weld overayAplugofthesarme bese natal and of uniform thickness, aoteacoeding the malt average thickness on which the verays wil be permanettly applied, shall be falrpeneration welled around the » “pening an sh with the outside surface ofthe pres: tre componeat. Alternatively an equivalent volume of base metal may be roved fom the inside surtace of the mockup By machining or grinding, without the ‘ed for welding in a closure pl. 3.21.3 Overay Thickness. Overlay section thicke ness (posit + base metal), represented by the dimer lon an in Fig forthe thinned aren ofthe mock "up shall be not grestr than 873% ofthe nominal wall ‘ficknos. This intended to provide a conservative ‘Tlenes for te qaliaton of te overt deg 3.2.14 Burst Pressure. To qual a wept desgn foe general pplication (on pressure components in the sme orlenation or atthe same lesion on tings), burst prewure all be not lens has pols ‘outside diameter of the pressure component, ‘mm Gi) ‘minimum acceptable burst pressure, MPa 09) reported actual tense strength, MPa (pi), of the base material ested {= tainimum epecified thickness (excluding ‘raufacturng tolerance) of base atrial tested, mn Gi) 3.2.15 Peaibitty Analysis. If flibility analysis as required By the engin code of construction, the ‘Sfct ef the weld over shall be rconied withthe triginal analysis or lied in accordance wit para 3133, 3.22 Burst Testing Method WARMING: Hydro toting hs the potent ese "oie dag trope ies sl Bethany ‘lasted fr sfty and conta of debi om component Pe el 3.22.1 Pump Selection. ‘The pump station uscd for burst testing shouldbe capble of excendng the ‘maxim calculated bust pre The pump should ‘capable providing» minimum of 25 overeat toallowforburt pressure variations rom wall chess tolerances, wold reinforcement le In most cas the ‘sctual burst pressure will aceed the calculted value bye small margin, 2.2.2.2 Burst Test tings and Gages. Al ities hoses and gages shal be ated fra working reste ‘qual to oF greater than the pump rating. Fittings tilached tothe pressure comporent mockup aould Be headed info the end belle of the mock-up and then ‘scl welded wo prevent leakage. Gages sal berated for ‘working presses at orabove the pump pressure ating,a = Ail 22 and shal be caltated to a pressure standard, traceable farthe National Institute of Standards and Testing (MIST), or equivalent, by a reputable Inboratory. The expect burst pressure af the compnent Being teed all fall within anefourh to wotheds ofthe gage ating, so as tobe nthe mast accurate portion of the fige mensucmnent ange ‘4 FABRICATION ‘This section deseribes application methods and techniques fr applying weld overs om degraded ‘hining stot pressure components Thissecton should be considered as generl requirements for overlying and sal be used in conjunction with the equiements ‘of the applicable code of construction or post ‘onsraction code ‘4.1 Prorpair Inspection Requirements 4.2.1 Evaluation of Base Material. ‘The material, beneath the surface to be weld over shal be eval sted to establish the average wall thickness and the ‘extent and coniguraion ef thinning tobe reinforced by the weld overlay. Consideration shoul also be given the cise and sae of deterioration (I the case oF he thinng not knoven or understood then a mater engine should be consoled to approve the repair tec= figure and procedures to ensure thatthe ropa il fot cause an unaccepable change nthe deterioration ‘mechanism 4.4.2 Volumetsc Examination. The wor sal deter ‘nine tat eracking hat not oor pir fo consnenc- Ing the repair. The area of the existing pressure ‘component to whic the weld overly is 0 br applied, ‘ould be vlumetzlly amined pir performing the weld overay, 4.41.3 Surface Examination. The entire suface, to which the weld overay is to be appli, shall be exam ned sing epproprinte NDE techniques (0 very suse face quality poor to welding, Acceptance criteria shall boinaecondance with theappliisecodeof cnsteuction or postconatrcton cade ‘4.2 Presepair Surface Preparation ‘42.1 General The surice tobe overiaid shall be fre rom an sale pain coatings, oF other contami rants: Grinding or wire trashing tay be neces 10 remove surface oxides or protective costings. 4.22 Solvent leaning. immedistely prior to weld ng, thelial weld sre shouldbe thorough cleaned sing slvent, sch as aectona, to remove any waces follor eave Thisprocedure wil alobelpin removing teacor of moisture Surface contaminants ay Teal porosity and other welding defects, which may ‘versely affect the welding qual A ean surface wil « lo assist in peniting more accurate nondestructive ‘samination acest the press component wi Segradaton. 4.2.3 Leakage Ropar. Allleakage shall be repaied roe performing the weld overlay rep If suicent ‘atrial is avaluble,peening may be ted 9 ele off the leakage and pert sal welding, Another option 1S application of series of overlapping weld fends Immediatly adjacent tothe leakage: Once sufficient materia is avaiable, peen to close ofthe leakage anc petoem tin ws ding 42.4 Special Considerations. Sel welded reals ‘condacted on ine, of to systems containing hazartous raters, may equle spel considerations chat ae utd the scope of this Artie {4.3 Weld Overlay Placement 43.4 Mapping of Degraded Aes. The area that determined to be degrade below the aloeble wall thickness shouldbe clearly mapped-out onthe pressure ‘component surlace, ising ascribe or other sltable ‘racking technique ‘4A Electrode Size and Filler 4.4.3 Weld Metal Requirements. Therein weld ‘metal shall conform to paca 311 44.2 Wal Thickness Determination. Piet nti tion of welding, the remaining wall thickness shall be ‘etermincd to ensure tat the prope electrode size fs ‘sed to prevent barn through Of the presse compo” rent wal. 443 MinknaingPereteation. Iisnecesary tomin- Iimize penetration curing the fist layer thus smaller ameter clctodes should be used. in doubt about tho accuracy ofthe wall thickness, such a i the ease of pting, the smallest possible electrode should be selected, A.A Peetode Size, ‘The coctode size shold not exceed the remaining bate materia wall thickness 5 Bure-Though. The potential forbum-through and consequences thewof, shall be evaluated, 45 Welding Process and Techniques 4.5.1 Welding Procedure Qualification. Overlay welding shall be performed using a qualified groove ‘Welding procedure, In accordance with ASME BPVC Section TX, oF a8 raquled by the applicable code of constuction oe pastenstrcton cage 4.5.2 Welder Qulifistion. Welders performing ‘overlay welds shal be qualified in accordance sth ‘ASME BPV Section I as equ by the applicable ‘odo of construction oe post-constuction cade.45.3 Welding Processes. Typical welding} for these pati include, but ar nt limited to, SMAW and GTAW, 45.4 Well Thickness Considerations. Pressure com ones ith wall thickness less than the diameter of the electrode shuld be depressurized before welding 5 Depressuization. Consideration should be siven to depressurzing the system before welding ‘Alematvely appeopite ivcrvie welding techs (ops provided it ADM RD 220) should Ea ured ‘45.6 Heat eatment. Hen treatment shall be pet formed in aesordanee with the applicable code af com struction, post construction code or engineering desig, “eat treatment shall only be apolied to equipment that |s repaired wile notin serve. Tn some cases, hea ttenment maybe ruied to meet sevice conditions proces und may ot be required by code of construction (ei for 5 eacking) ‘45.7 Temper Bead Technique, ‘Temper bead tec> niques, s permite in the applicable post-constuction odes, ay be used on carbon steele iw lly steel toavoid the nse for high temperature eal tates ‘vod use of temper bead methods where proest oF ‘service condions mandate use of ha! ueatment (8, HS, HCN, HP, 45.8 Bead Overlap. A bod overlp of approx imately 5% sould be maintained toreduce the potential fortumnthrogh ant set n absning prope Bec Placement, nome cases, wastage may have progressed tothe polnt where thee is kof burning through the ‘omponent when depositing the fit ayers). To prevent Durnawough in such situations, the fst bead shoul Ibe depated where the emaining shickness i rate, then subsequent beads should be overapped fo ep acre the thinner ae 45.9 Welding Techoiques. ‘The ochniques spent in paras 4591 through 459.4 may be used 4.5.9.4 Considerations Prior Welding. Once he ara o be rpated has been mapped and te presse Component surface cleaned, welding may be fniiated tp the fit layer Welding parameters should provide SS lowe ofa hen! input a pone hile maining sion. This not only redocer the potential for bur trough but also edaces the width f the finshed heat sifeced zone 4.5.9.2 Initial Welding Pass. ‘The frst weld passe) should follow the outer perimeter ofthe weld very location 10 (a) provide an outer gage forthe welder {@ Improve the hesbatlected zane quality by in rating the poten fora a, untempered weld pose tn the base metal surface for catbon and low allo sel ‘materials: After completion ofthe perimeter weld pas, 5 ‘he fst layer may be welded in accordance with the (qualified wld procedure 45.93 Subsequent Welding Passes. Subcoquont ‘welding pases may’ be completed in anormal fashion, however cae should be taken with the weld passes a ‘he edger the veray to matin the edge angle 0 laper toequal ori tan that gualiod. Ar edge age 130 deg is ecommended ane meets one of te prov ‘Sionsforo prequel design The taper angles impor- tanta minimizes th ste intent efecto he ‘veray eto the changes surface geomet 45.94 Edge Taper Angie. The maximum allow ble edge laper ange 48 deg 5 EXAMINATION “The Inepections specified In paras, 5.1 through 54 apply to weld overay sepals. 5: Surface Examination ‘The completed weld avery shal be examined using the lguid penetrant or magnetic particle method sity the surface examination scceptanc® c= ‘ofthe applicable code of construction or post- ‘onstruction code 5:2 Overly Thickness Adequate wall thickness of weld overlay and elvan extn base metal shal be erie by taconite 5.3 Volumetric Examination When volumetric examination is roquzed by the applicable cage of consriction or pos-constracion ‘odo, he fl volume ofthe inshed overisy oxen the tapered edges, but including the volume of base ‘etl raguted forthe design ie ofthe overly hal ‘be examined y elther the ultasnie or tadlogrophic method. The real shall satisfy the acceptance calela Forpith weld of he splicablecode of construction oF osteonriructioncode fthere ae noaccepance cetera Forsractarl ovriny, bute o adding 5. Surface Finish Grinding and machining ofthe tweed ove {ace nay Be used fo enpove the urace inh for such cxaminations, provided the overlay thickness isnot reduced below design requirements 64 Pressure Testing the preture component conbe alate fr pressure testing all opie lotions shall be pressure tested if