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5.3 Post Construction Codes

Overview 0f ASME PCC-2

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Integration Of In-service Inspection and Repair Codes and Standards

Scope of PCC-2 Standard

Covers equipment within the scope of API and ASME Pressure Equipment Codes and Standards Standards, including:
Piping and pipelines including piping components (such as valves, flanges and fittings) Boilers/Heaters Pressure vessels (including heat exchanger bundles) Storage tanks.

Coverage is not limited to equipment built to ASME Codes Covers repairs after equipment has been placed in service. Repairs during construction are covered by the new construction codes.

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Organization of PCC-2 Standard

This Standard is divided into five Parts.
Part 1 covers the scope, scope organization, organization and intent and is applicable to all articles in this Standard. Table 1 provides guidance for the applicability of repair methods listed in this Standard. Part 2 covers repair methods and techniques that include the use of welding, brazing, soldering, or other methods involving metal deposit. Part 3 covers mechanical repairs, with or without sealant, such as bolted clamps or fixtures and includes all repair methods not covered in Part 2 or Part 4. 4 Part 4 covers repairs using nonmetallic means, such as nonmetallic liners and wraps, and bonding (e.g., joining by epoxy), including bonding of metallic components. Part 5 covers examination and testing methods and techniques.

Table 1 Guide for the Selection of Repair Technique

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Organization of PCC-2 Standard

Standard Outline/Format for Each Article:
Description of the repair Limitations and Precautions associated with the repair Design/Fabrication issues associated with the repair Examination and Testing QA/QC practices following p the repair Additional references

PCC-2: Welded Repair Articles

Repair Method for Butt Welded Insert Plates in Pressure Components External Weld Overlay to Methods for Internal Thinning Seal Welding Threaded Connections and Seal Welded Repairs Full Encirclement Steel Sleeves for Piping Welded Leak Enclosures Fillet Welded Patches with Reinforcing Plug Welds Alternatives to Traditional Welding Preheat Alternatives to Post Weld Heat Treatment In-Service Welding onto Carbon Steel Pressure Components or Pipelines Weld Buildup, Weld Overlay and Clad Restoration Fillet Welded Patches Threaded or Welded Plug Repairs

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PCC-2: Mechanical Repair Articles

Replacement of Pressure Components Freeze Plugging Repair of Damaged Threads in Tapped Holes Flaw Excavation and Weld Repair Flange Refinishing Mechanical Clamps Pipe Straightening Repair Guidelines for Damaged Anchors in Concrete Hot and Half Bolting Removal Procedures Inspection and Repair of Shell and Tube Heat Exchangers

PCC2: Non-Metallic Repair Articles

Non-Metallic Composite Wrap Systems for Pi i and Piping d Pipelines: Pi li High Hi h Risk Ri k Applications A li ti Non-Metallic Composite Wrap Systems for Pipe: Low Risk Metal Pipe Non-metallic Internal Lining for Pipe-Sprayed Form for Buried Pipe

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PCC-2: Examination & Testing Articles

Examination and testing requirements for each specific ifi type t of f specific ifi repair i are covered d in i the last section of each article However, Two Separate Generic Examination and Testing Articles are also included:
Pressure and Tightness Testing of Piping and Equipment NDE in Lieu of Pressure Testing

Repair Life Many M of f th the repair i techniques t h i included i l d d in i this thi Standard St d d are considered to be permanent, intended to remain in place for the life of the repaired component. Others may only be suitable for short-term service, and should be replaced with a more permanent repair at the appropriate opportunity. The anticipated life of the repair depends on many circumstances, and could include consideration of risk. As such, this Standard does not classify repair methods as permanent or temporary.

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Highlights of ASME PCC-2

Welding - Requirements for welding, including qualification of welding procedures, procedures welders, welders and welding operators, should generally follow an applicable code of construction or an applicable postconstruction code, except when otherwise specified herein. Allowable Stress - Calculations involving the allowable stress use the allowable stress from the original code of construction or an applicable postconstruction code, unless otherwise specified in specific articles.

ASME PCC-2 Article 2.1 - Butt-Welded Insert Plates in Pressure Components

The repair of pressure components by butt-welded insert plates involves the replacement of pressure boundary material in a pressure component with an insert plate attached by full penetration butt welds. This repair method is applicable to cylindrical, spherical, and conical shells and to flat pressure components. p It may y be used for single g and double curvature shells. It may also be used on other pressure components (such as formed heads) if the curvature of the replaced section matches the curvature of the original pressure part.

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Fig. 1 Flush Insert in Pipe or Tube

NOTES: (1) Side view of cutout in pipe or tube with ith edge d b bevels. l (Fi (Fig. 1 1shows h singlei l grooved joint detail with 25 deg to 35 deg edge bevel in pipe or tube. Other joint details and edge bevels may be used, as appropriate for a particular weld joint.) (2) Plan view of insert with edge bevels. (Fig. 1 shows an insert with one-sided joint detail.) (3) Side view of the insert with edge bevels. (Other joint details and edge bevels may be used, as appropriate for a particular weld joint.) (4) Side view of welded insert in pipe or tube.

Table 1 Guide for the Selection of Repair Technique - Notes

(1) This method may apply to replacement of nozzles, flat spots, and dents. (2) See Part 2, Article 2.1, Limitations. (3) This repair technique applies to seal welded threaded joints for leak tightness. (4) Welded leak box repair applies to leaking flanges, valves, pipe components, and welded and mechanical joints. (5) For internal defects, the cause of defect shall be understood or arrested or a Type B sleeve is recommended. (6) Alternative provisions for weelded repair. (7) Also may apply to new construction or to all methods requiring welding. (8) Generally appropriate for surface welding on carbon steel substrates. (9) This technique is used for isolating sections of pipes. (10) R Repair i of f damaged d d threads th d in i stud t d holes. h l (11) Also applies to the repair of hardened surfaces. (12) Radial cracks. (13) Gasket and packing leaks p Y. (14) Pipe straightening. (15) Repair of damaged anchor in concrete. (16) This is not a repair technique; however, it may apply to most methods of repair. (17) This is an alternative to pressure testing.

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Fig. 2 Flush Insert Plate (With or Without Nozzle/Manway) With Its Butt Weld Intersecting Existing Butt Weld in Shells or Heads
NOTES: (1) Existing butt weld in vessel shell or head. head (Fig (Fig. 2 shows butt weld in a cylindrical shell.) (2) Thirty deg minimum angle. (3) Full RT or UT, or MT or PT both sides of existing butt weld, 100 mm (4 in.) min. each side of intersection with insert plate. (4) Insert plate butt weld. Full RT or UT, or MT or PT both sides of weld. (5) For nonpostweld heat-treated carbon and low alloy steel nozzle/manway assemblies, 150 mm (6 in.) minimum between the toe of the

ASME Post Construction Subcommittee On Repair And Testing

Traditionally, ad t o a y, International te at o a Codes and a d Standards Sta da ds have ave focused on new construction because these standards are essential for both domestic and international trade. In the past, maintenance and inspection of fixed equipment have been handled on a local, regional or industry sector basis. In some cases, rules for maintenance and inspection are established t bli h d by b regulatory l t authorities. th iti More recently, it has been recognized that broadly based international standards for maintenance and inspection are desirable to ensure worldwide acceptance of the best available approaches.

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ASME PCC-2: Repair of Pressure Equipment and Piping

Provides methods for repairs of equipment & piping within the scope of ASME Pressure Technology Codes & Standards after they are placed in service. May be temporary or permanent, depending on the circumstances. Provides only technical procedures and information; administrative or policy requirements are outside its scope.

ASME PCC-2: Organization

Section 1 covers Scope, Organization & Intent Section 2 repair methods involving welding, brazing, soldering, or other methods involving metal deposit Section 3 mechanical repairs, with and without sealant, such as bolted clamps & fixtures Section 4 repairs using nonmetallic means, such as nonmetallic liners and wraps, raps and bonding Section 5 covers examination and testing methods and techniques

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Mechanical Clamp Repair

Genera al wall thinning Local wall w thinning Pitting Gouges Blisters s Circum mferential Cracks Lamina ations Longitu udinal cracks Other

Mechanical Clamp

(1)

Y = Generally appropriate. S = Although may be acceptable, is not generally used for this condition. R = May be used, but requires special cautions. N = Not generally appropriate.
Note (1): Normally, mechanical clamps are used to contain leaks at packings, and at flange and gasketed joints, or to contain leaks/potential leaks due to

Welded Leak Box Repair

Gener ral wall thinning Local wall w thinning Pitting g Gouge es Blister rs Circum mferential Cracks s Laminations Longit tudinal cracks Other

Leak Repair Box

(1)

Y = Generally appropriate. S = Although may be acceptable, is not generally used for this condition. R = May be used, but requires special cautions. N = Not generally appropriate. Note (1) Welded leak repair box applies to leaking flanges, valves, pipe components, welded

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Weld Overlay Repairs on Carbon Steel Piping

The weld overlay repair provides a practical technique for repairing degraded walls of piping components. As shown above, the weld overlay restores the load carrying capability and integrity of the repaired location through the application of external weld material.

External Weld Overlay Repair Methods for Internal Thinning - 1

When appropriate, applying a weld overlay repair to y thinning g pressure p component p the exterior of a locally (pipe/pressure vessel) will provide the necessary structural reinforcement and will eliminate the need for either total replacement of the component or an internal weld repair. A weld overlay procedure may be used to structurally restore steel components (CS, low-alloy, or austenitic SS materials suitable for welded construction) to the appropriate wall thickness without resorting to replacement efforts. In some cases, it may be possible to perform a repair while the component is in operation.

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External Weld Overlay Repair Methods for Internal Thinning - 2

A weld overlay shall not be used for structural reinforcement when there is indication of any form of cracking. The user shall evaluate the flammability, volatility, or potential reactions of the medium within the pressure component prior to application of any welding process. Examples E l of f process media di that h should h ld be b properly l flushed from the system prior to repair include hydrogen, hydrogen cyanide, oxygen, alkaline/caustic materials, butadiene, acetylenic compounds, H2S, chlorine and acids.

External Weld Overlay Repair Methods for Internal Thinning - 3

Genera al wall thinning Weld Overlay Repair N Local wall w thinning Y Pitting Y Gouges Y Blisters s S Circum mferential Cracks Lamina ations N N Longitu udinal cracks N Other (1)

Y = Generally appropriate. S = Although may be acceptable, is not generally used for this condition. R = May be used, but requires special cautions. N = Not generally appropriate.
Note (1): Normally, mechanical clamps are used to contain leaks at packings, and at flange and gasketed joints, or to contain leaks/potential leaks due to

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External Weld Overlay Repair Methods for Internal Thinning - 4

The weld overlay shall meet the following: The nominal chemistry of the deposited weld metal should match h the h base b material. i l The tensile strength of the deposited weld metal shall be at least that of the base metal to which it is applied. The design of the overlay should not hinder post-repair examinations and evaluations or any pre-service examinations. The weld should extend, at full thickness, a minimum di t distance B in i each h direction di ti b beyond d th the affected ff t d base b metal t l (unless otherwise justified by a fitness for service assessment). B = 3/4 (Rtnom)1/2 R = outer radius of the component, or D/2. tnom = nominal wall thickness of the component.

External Weld Overlay Repair Methods for Internal Thinning - 5

The edges of the weld overlay should be tapered to the existing pressure component surface at a maximum angle , of 45 degrees. angle, degrees The thickness of the overlay should be uniform except for the tapered edges. The thickness should be sufficient to maintain the predicted life of the repair. All corners of the overlay should have a radius, r, not less than the e overlay ove y thickness. c ess. Any corrosion allowance that is determined to be necessary should be added to these dimensions. The predicted maximum degradation of the overlaid pressure component, and the overlay, over the design life of the restoration should be analyzed.

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External Weld Overlay Repair Methods for Internal Thinning - 6

In addition, two or more overlays should not be spaced any closer than 3/4 (Rtnom)1/2 between the toe of each overlay. The thickness of the completed overlay, W, should not exceed the nominal thickness of the pressure component. Configurations not meeting these requirements shall be evaluated based on engineering analysis or testing.

Overlay Qualification Requirements - 1

Application of weld overlays on straight piping sections and associated welds to correct limited degradation may be considered a pre-qualified design and will be exempt from an engineered design qualification or a proof test qualification if all of the following conditions are met:
1 The maximum design temperature does not exceed 1. 340oC (650oF). 2. The specified nominal thickness of the existing base metal is at least Schedule 40 or Standard Wall, whichever is less.

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Overlay Qualification Requirements - 2

3. The maximum angle of the taper does not exceed 30 degrees ( in Figure 1). 4. The finished overlay is circular, oval, full circumferential, or rectangular l in i shape. h 5. For each repair, the maximum dimension (L, length along pipe axis or C, circumferential width) compensated by a circular, oval, or rectangular overlay does not exceed the lesser of the nominal outside diameter of the pressure component or 200mm (8 inches). A full-circumferential overlay is only limited in the axial dimension, L. 6 Rectangular overlays are aligned parallel with or 6. perpendicular to the axis of the pressure component, and corners are rounded with radii not less than the overlay thickness. 7. The distance between the toes of adjacent overlays is not less than 3/4 (Rtnom)1/2

Overlay Qualification Requirements - 3

8. The maximum axial dimension and area of base metal predicted to be below the required thickness over the remaining life of the repair does not exceed that defined by: Lmax = k1Do + k2 Amax = 0.455 Do k3

Lmax = maximum axial dimension of base metal predicted to degrade below the required thickness over the remaining life of the repair, mm (in.). Amax =maximum area of base metal predicted to degrade below the required thickness over the remaining life of the repair, mm2 (in2). ) Do = pressure component nominal outside diameter, mm (inches).
Do < DN300 DN300 - 600 k1 0.21 0.11 k2 14 mm (0.55 inch) 46.7 mm (1.84inch) k3 581 mm2 (0.9 in2) in2) 516mm2 (0.8

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Overlay Qualification Requirements - 4

9. The minimum thickness of the overlay shall be sufficient to restore the nominal wall thickness of the pressure component This can be accomplished by subtracting the component. remaining thickness from the nominal thickness of the component to obtain the required overlay thickness. 10.If flexibility analysis was required by the original code of construction, the effect of the weld overlay should be reconciled with the original analysis. In this case, for rectangular-shaped overlays on straight pipe, a Stress Intensification Factor (SIF) of 2.1 shall be applied to the overlay. l The weld overlay may be qualified by an engineered design. As an alternative to the engineered design of weld overlays, a proof test qualification may be performed through a satisfactory burst test mock-up.

Flaw Excavation
Genera al wall thinning
NA

Flaw excavation

NA

Y = Generally appropriate. S = Although may be acceptable, is not generally used for this condition. R = May be used, but requires special cautions. N = Not generally appropriate. Note (1): Also applies to the repair of hardened surfaces.

Local wall w thinning

Pitting
Y

Gouges
Y

Blisters s
Y

Circum mferential Cracks Lamina ations

Y Y

Longitu udinal cracks

Y

(1)

Other

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Flaw Excavation - 2
Material or weld flaws open to the surface are typically removed by a mechanical (abrasive) method.
1. If the remaining wall thickness of the excavation, with allowance for future corrosion, is greater than the minimum required wall thickness required by the construction t ti or post-construction t t ti code d (such ( h as the local thin area rules of API 579) the excavated area may be blended to a 3:1 or smoother profile slope, and left as-is for return to service.

Flaw Excavation - 3
2. .W When e the t e removal e ova o of a flaw aw p produces oduces a remaining e a g wall thickness below the limit permitted by the construction or post-construction code, including allowance for future corrosion, then the cavity shall be repaired by deposition of weld metal or analyzed for fitness-for-service.
When the depth of material excavated necessitates a weld repair, repair the cavity shall be prepared for welding. welding Either during or following defect removal, the excavation shall be shaped to provide adequate access for the welding operation in order to facilitate proper fusion, and avoid slag entrapment, or lack of penetration

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Flaw Excavation - 4
Fabrication - The following steps are generally followed to excavate a flaw: 1. Locate and expose the flaw. Characterize the flaw (size, depth, orientation) to the extent possible. If the flaw is a crack, the crack tips may be rounded by drilling to preclude crack from propagating during its excavation. 2. Remove the flaw by grinding, machining, honing or thermal gouging. In selecting and applying a removal process refer to the guidance process, g idance in Sections 2 and 3.. 3 3. Verify defect removal by inspecting the cavity using visual examination (VT), and liquid penetrant testing (PT), or magnetic particle testing (MT) or eddy current testing (ET) as appropriate.

Grinding Repairs
Grinding of cracks, arc burns, gouges and grooves is an acceptable method of permanent repair, repair provided the length and depth of metal loss is in accordance with the formula given below. For arc burns, confirmation of complete removal of altered metallurgical structures by etching the ground area with a 10% solution of ammonium persulfate or a 5% solution of nital is recommended.

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Grinding Repairs
Areas to be repaired by grinding shall be thoroughly cleaned before grinding is initiated initiated. Grinding shall be performed to produce a smooth transition between the surface contour of the repaired area and the surrounding pipe surface. External metal loss resulting from grinding to a depth of 40% of the nominal wall thickness of the pipe is permitted, i d provided id d that h the h longitudinal l i di l length l h of f the h ground area does not exceed length L as determined by the following formula: L = 0.441 B1 (Dt)0.5

Grinding Repairs
Where L = maximum allowable longitudinal length of the metal loss area resulting from a grinding repair, inches. D = nominal outside diameter of pipe, inches. T = nominal wall thickness of pipe, inch. B1= a value equal to 4 for maximum depths up to and including 13% of the nominal wall thickness. = a value determined from the following equation for maximum depths greater than 13% of the nominal wall thickness up to and including 40% of the of the nominal wall thickness: B1 ={[(c/t)/ (1.1 c/t) 0.11)] 2 1} 0.5 c = maximum depth of the ground area, inches.

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Grinding Repairs
For gouges, grooves and cracks, confirming complete l t removal l of f the th defects d f t by b using i dye d penetrant or magnetic particle inspection and measuring the remaining wall thickness using a mechanical or ultrasonic technique is recommended.

Visual Robotic Welding (VRW)

The VRW process allows for free-hand welding in areas inaccessible to a human and where automated welding g is not possible because of unknown or changing weld conditions. Visual Robotic Welding has been designed for remote internal pipe repair but this technique could be adapted to other situations. The VRW process combines closed loop control of a specially developed robotic welding arm and an adjacent robotic camera arm. Both arms articulate and have the ability to move about five independent axes. The current prototype is sized to repair pipes from 12 to 24 in. diameter

N. Al-Khirdaji, AZTech Sr. Consultant

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