Repair of Pressure Equipment and Piping

A N A M E R I C A N N A T I O N A L S T A N D A R D

ASME PCC-2–2006

Repair of Pressure Equipment and Piping

AN AMERICAN NA TIONAL S T AND ARD

Three Park Avenue • New York, NY 10016

Date of Issuance: January 15, 2007

The next edition of this Standard is scheduled for publication in 2007. There will be no addenda or written interpretations of the requirements of this Standard issued to this edition.

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This code or standard was developed under procedures accredited as meeting the criteria for American National Standards. The Standards Committee that approved the code or standard was balanced to assure that individuals from competent and concerned interests have had an opportunity to participate. The proposed code or standard was made available for public review and comment that provides an opportunity for additional public input from industry, academia, regulatory agencies, and the public-at-large.

ASME does not “approve,” “rate,” or “endorse” any item, construction, proprietary device, or activity.

ASME does not take any position with respect to the validity of any patent rights asserted in connection with any items mentioned in this document, and does not undertake to insure anyone utilizing a standard against liability for infringement of any applicable letters patent, nor assumes any such liability. Users of a code or standard are expressly advised that determination of the validity of any such patent rights, and the risk of infringement of such rights, is entirely their own responsibility.

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without the prior written permission of the publisher.

The American Society of Mechanical Engineers Three Park Avenue, New York, NY 10016-5990

Copyright © 2007 by

THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS

All rights reserved Printed in U.S.A.

CONTENTS

Foreword iv

Preparation of Technical Inquiries v

Committee Roster vi

Part 1 Scope, Organization, and Intent 1

Part 2 Welded Repairs 4

Article 2.1 Butt-Welded Insert Plates in Pressure Components 4

Article 2.2 External Weld Overlay to Repair Methods for Internal Thinning 10

Article 2.3 Seal-Welded Threaded Connections and Seal Weld Repairs 16

Article 2.4 Welded Leak Box Repair 18

Article 2.5 Welded Lip Seals (in the course of preparation) 22

Article 2.6 Full Encirclement Steel Reinforcing Sleeves for Piping 23

Article 2.7 Repair Method Using Fillet Welded Lap Patches With Reinforcing Plug

Welds (in the course of preparation) 29

Part 3 Mechanical Repairs 30

Article 3.1 Replacement of Pressure Components 30

Article 3.2 Freeze Plugs 32

Article 3.3 Damaged Threads in Tapped Holes 37

Article 3.4 Flaw Excavation and Weld Repair 47

Article 3.5 Flange Refinishing 54

Article 3.6 Mechanical Clamp Repair 57

Article 3.7 Pipe Straightening or Alignment Bending 61

Article 3.8 Damaged Anchors in Concrete 64

Article 3.9 Valves With Pressure-Seal-Type Bonnets (in the course of preparation) 73

Article 3.10 Hot Bolting (in the course of preparation) 74

Part 4 Nonmetallic and Bonded Repairs 75

Article 4.1 Nonmetallic Composite Repair Systems for Piping and Pipework:

High-Risk Applications 75

Article 4.2 Nonmetallic Composite Repair Systems for Piping and Pipework:

Low-Risk Applications 105

Article 4.3 Nonmetallic Internal Lining for Pipe: Sprayed Form for Buried Pipe 118

Part 5 Examination and Testing 128

Article 5.1 Pressure and Tightness Testing of Piping and Equipment 128

Article 5.2 Repairs and Alterations Without Pressure Testing (in the course of

preparation) 142

iii

FOREWORD

ASME formed an Ad Hoc Task Group on Post Construction in 1993 in response to an increased need for recognized and generally accepted engineering standards for the inspection and mainte- nance of pressure equipment after it has been placed in service. At the recommendation of this Task Group, the Board on Pressure Technology Codes and Standards (BPTCS) formed the Post Construction Committee (PCC) in 1995. The scope of this committee was to develop and maintain standards addressing common issues and technologies related to post-construction activities and to work with other consensus committees in the development of separate, product-specific codes and standards addressing issues encountered after initial construction for equipment and piping covered by Pressure Technology Codes and Standards. The BPTCS covers non-nuclear boilers, pressure vessels (including heat exchangers), piping and piping components, pipelines, and storage tanks.

The PCC selects standards to be developed based on identified needs and the availability of volunteers. The PCC formed the Subcommittee on Inspection Planning and the Subcommittee on Flaw Evaluations in 1995. In 1998, a Task Group under the PCC began preparing Guidelines for Pressure Boundary Bolted Flange Joint Assembly. In 1999, the PCC formed the Subcommittee on Repair and Testing. In 2002, the Subcommittee on Flaw Evaluation was dissolved, and replaced by the Joint ASME/API Committee on Fitness for Service. Other topics are under consideration and may be developed into future guideline documents.

The subcommittees were charged with preparing standards dealing with several aspects of the in-service inspection and maintenance of pressure equipment and piping. The Inspection Planning Standard provides guidance on the preparation of a risk-based inspection plan. Defects that are identified are then evaluated, when appropriate, using the procedures provided in the Fitness for Service. Finally, if it is determined that repairs are required, guidance on repair procedures is provided in the Repair of Pressure Equipment and Piping Standard. These documents are in various stages of preparation.

None of these documents are Codes. They provide recognized and generally accepted good practices that may be used in conjunction with Post-Construction Codes, such as API 510, API 570, and NB-23, and with jurisdictional requirements.

The first edition of ASME PCC-1, Guidelines for Pressure Boundary Bolted Flange Joint Assembly, was approved for publication in 2000. ASME PCC-1-2000 was approved by the American National Standards Institute (ANSI) as an American National Standard on November 15, 2000.

The first edition of ASME PCC-2, Repair of Pressure Equipment and Piping, was approved for publication in 2004. This revision was approved by ANSI as an American National Standard on April 17, 2006.

iv

PREPARATION OF TECHNICAL INQUIRIES

INTRODUCTION

The ASME Post-Construction Standards Committee will consider written requests for interpre- tations and revisions of the rules of this Standard and develop new rules if dictated by technologi- cal development. The Committee’s activities in this regard are limited strictly to interpretations of the rules or to the consideration of revisions to the present rules on the basis of new data or technology. As a matter of published policy, ASME does not “approve,” “certify,” “rate,” or “endorse” any item, construction, proprietary device, or activity, and, accordingly, inquiries requiring such consideration will be returned. Moreover, ASME does not act as a consultant on specific engineering problems or on the general application or understanding of the rules. If, based on the inquiry information submitted, it is the opinion of the Committee that the inquirer should seek professional assistance, the inquiry will be returned with the recommendation that such assistance be obtained.

An inquiry that does not provide the information needed for the Committee’s full understanding will be returned.

REQUIREMENTS

Inquiries shall be limited strictly to interpretations of the rules or to the consideration of revisions to the present rules on the basis of new data or technology. Inquiries shall meet the following requirements:

1. Scope. Involve a single rule or closely related rules in the scope of the standard. An inquiry letter concerning unrelated subjects will be returned.

2. Background. State the purpose of the inquiry, which may be either to obtain an interpretation of rules of this Standard, or to propose consideration of a revision to the present rules. Provide concisely the information needed for the Committee’s understanding of the inquiry, being sure to include reference to the applicable Part, Article, Edition, Addenda, paragraphs, figures, and tables. If sketches are provided, they shall be limited to the scope of the inquiry.

3. Inquiry Structure

   1. Proposed Question(s). The inquiry shall be stated in condensed and precise question format, omitting superfluous background information, and, where appropriate, composed in such a way that “yes” or “no” (perhaps with provisos) would be an acceptable reply. The inquiry statement should be technically and editorially correct.

   2. Proposed Reply(ies). Provide a proposed reply stating what the inquirer believes that the standard requires.

If in the inquirer’s opinion, a revision to the standard is needed, recommended wording shall be provided in addition to information justifying the change.

SUBMITTAL

Inquiries shall be submitted in typewritten form; however, legible handwritten inquiries will be considered. They shall include the name and mailing address of the inquirer, and may either be sent by email to SecretaryPCC@asme.org, or by mail to the following address:

Secretary

ASME Post Construction Three Park Avenue

New York, NY 10016-5990

v

ASME PRESSURE TECHNOLOGY POST CONSTRUCTION COMMITTEE

(The following is the roster of the Committee at the time of approval of this Standard.)

STANDARDS COMMITTEE OFFICERS

C. Becht, Chair

J. R. Sims, Vice Chair

U. D’Urso, Secretary

G. A. Antaki, Washington Group

J. L. Arnold, Alstom Power, Inc.

J. E. Batey, The Dow Chemical Co.

1. Becht, Becht Engineering Co., Inc.

2. L. Berger, PPL Generation LLC

P. N. Chaku, ABB Lummus Global, Inc.

C. D. Cowfer, Cowfer Consulting

STANDARDS COMMITTEE PERSONNEL

E. Michalopoulos, City of Kozani

K. Mokhtarian, Consultant

C. C. Neely, Becht Engineering Co., Inc.

J. T. Reynolds, Shell Global Solutions US, Inc.

S. C. Roberts, Shell Global Solutions US, Inc.

C. D. Rodery, BP

C. W. Rowley, The Wesley Corp.

U. D’Urso, The American Society of Mechanical Engineers

P. C. Hackford, State of Utah

W. J. Koves, UOP LLC

D. A. Lang, FM Global

C. R. Leonard, Life Cycle Engineering

M. E. Schmidt, Consultant

J. R. Sims, Becht Engineering Co., Inc.

H. N. Titer, Mirant Mid-Atlantic

C. S. Withers, The National Board of Boiler and Pressure Vessel Inspectors

C. Becht, Chair, Becht Engineering Co., Inc.

G. A. Antaki, Vice Chair, Washington Group

REPAIR AND TESTING SUBCOMMITTEE (PCC)

W. F. Hart, Furmanite America, Inc.

D. B. Kadakia, T. D. Williamson, Inc.

U. D’Urso, Secretary, The American Society of Mechanical Engineers

L. P. Antalffy, Fluor Daniel

J. A. Brown, AREVA NP

P. N. Chaku, ABB Lummus Global, Inc.

W. D. Doty, Doty & Associates

N. Y. Faransso, KBR

S. J. Findlan, EPRI RRAC

P. C. Hackford, State of Utah

D. H. Hanrath, Consultant

1. F. Hantz, Exxon Mobil Research and Engineering Co.

2. R. Harley, General Physics Corp.

W. J. Koves, UOP LLC

K. Mokhtarian, Consultant

W. F. Newell, W. F. Newell & Associates, Inc.

J. T. Reynolds, Shell Global Solutions US, Inc.

S. C. Roberts, Shell Global Solutions US, Inc.

C. D. Rodery, BP

C. W. Rowley, The Wesley Corp.

S. C. Shah, Exxon Mobil Research and Engineering Co.

E. Upitis, Upitis & Associates, Inc.

R. H. Walker, Citadel Technologies

C. S. Withers, The National Board of Boiler and Pressure Vessel Inspectors

vi

ASME PCC-2–2006

STANDARD FOR THE REPAIR OF PRESSURE EQUIPMENT AND PIPING

PART 1

SCOPE, ORGANIZATION, AND INTENT

1. SCOPE

   This Standard provides methods for repair of equip- ment and piping within the scope of ASME Pressure Technology Codes and Standards1 after it has been placed in service. These repair methods include relevant design, fabrication, examination, and testing practices and may be temporary or permanent, depending on the circumstances.

   The methods provided in this Standard address the repair of components when repair is deemed necessary based on appropriate inspection and flaw assessment. These inspection and flaw evaluation methods are not covered in this document, but are covered in other post- construction codes and standards.

   Only technical procedures and information are pro- vided; administrative or policy requirements are outside of the scope of this Standard.

   
   

2. ORGANIZATION

   This Standard is divided into five Parts.

   1. Part 1 covers the scope, organization, and intent and is applicable to all articles in this Standard. Table 1 provides guidance for the applicability of repair meth- ods listed in this Standard.

   2. Part 2 covers repair methods and techniques that include the use of welding, brazing, soldering or other methods involving metal deposit.

   3. 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 compo- nents.

      
      

      1 Equipment and piping within the scope of ASME Pressure Technology Codes and Standards includes piping (including pipe- lines) and piping components (such as valves), boilers, pressure vessels (including heat exchangers), and storage tanks.

   5. Part 5 covers examination and testing methods and techniques.

      
      

3. INTENT

3.1

This Standard provides technical information, proce- dures, and recommendations for repair methods that were determined by consensus to be recognized and generally accepted good engineering practice. Where equipment repair is subject to jurisdictional regulation, jurisdictional approvals may be required.

3.2

The words should, shall, and may are used in the repair articles of PCC-2 and they have the following intent:

should: an action that is not mandatory. It indicates an action that when performed, is generally considered to be good practice; however, there are some circumstances when the action is not appropriate or required, so the word should is used to provide flexibility for the article to cover a broad range of circumstances. It is not mandatory unless so specified by others in the application of these articles.

shall: an action that is mandatory. It indicates an action that is an essential element of the repair method that cannot be eliminated.

may: indicates an action that is permitted, but not required.

3.3

For administrative requirements such as inspection, documentation, and quality control, the user is referred to an applicable post-construction code and to the juris- dictional requirements. In the absence of an applicable post-construction code or jurisdictional requirements, the owner of the pressure equipment or piping should establish the administrative requirements. A post- construction code is one that provides requirements and guidance for inspection and/or repair of equipment

1