Repair of Pressure Equipment and Piping

AN A MERICAN NA TIONAL S T AND ARD

ASME PCC-2–2015

(Revision of ASME PCC-2–2011)

ASME PCC-2–2015

(Revision of ASME PCC-2–2011)

Repair of Pressure Equipment and Piping

AN AMERICAN NA TIONAL S T AND ARD

Two Park Avenue • New York, NY • 10016 USA

Date of Issuance: February 23, 2015

The next edition of this Standard is scheduled for publication in 2017.

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

Copyright © 2015 by

THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS

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CONTENTS

Foreword iv

Preparation of Technical Inquiries v

Committee Roster vi

Correspondence With the PCC Committee viii

Summary of Changes ix

Part 1 Scope, Organization, and Intent 1

Part 2 Welded Repairs 5

Article 2.1 Butt-Welded Insert Plates in Pressure Components 5

Article 2.2 External Weld Buildup to Repair Internal Thinning 11

Article 2.3 Seal-Welded Threaded Connections and Seal Weld Repairs 17

Article 2.4 Welded Leak Box Repair 19

Article 2.5 Welded Lip Seals (in the course of preparation) 23

Article 2.6 Full Encirclement Steel Reinforcing Sleeves for Piping 24

Article 2.7 Fillet Welded Patches With Reinforcing Plug Welds 31

Article 2.8 Alternatives to Traditional Welding Preheat 37

Article 2.9 Alternatives to Postweld Heat Treatment 43

Article 2.10 In-Service Welding Onto Carbon Steel Pressure Components or

Pipelines 46

Article 2.11 Weld Buildup, Weld Overlay, and Clad Restoration 58

Article 2.12 Fillet Welded Patches 64

Article 2.13 Threaded or Welded Plug Repairs 70

Article 2.14 Field Heat Treating of Vessels 73

Part 3 Mechanical Repairs 81

Article 3.1 Replacement of Pressure Components 81

Article 3.2 Freeze Plugs 83

Article 3.3 Damaged Threads in Tapped Holes 88

Article 3.4 Flaw Excavation and Weld Repair 98

Article 3.5 Flange Repair and Conversion 104

Article 3.6 Mechanical Clamp Repair 107

Article 3.7 Pipe Straightening or Alignment Bending 112

Article 3.8 Damaged Anchors in Concrete (Postinstalled Mechanical Anchors) 115

Article 3.9 Valves With Pressure Seal-Type Bonnets (in the course of preparation) 124

Article 3.10 Hot Bolting (in the course of preparation) 125

Article 3.11 Hot and Half Bolting Removal Procedures 126

Article 3.12 Inspection and Repair of Shell and Tube Heat Exchangers 130

Part 4 Nonmetallic and Bonded Repairs 143

Article 4.1 Nonmetallic Composite Repair Systems: High-Risk Applications 143

Article 4.2 Nonmetallic Composite Repair Systems: Low-Risk Applications 181

Article 4.3 Nonmetallic Internal Lining for Pipe: Sprayed Form for Buried Pipe 195

Part 5 Examination and Testing 207

Article 5.1 Pressure and Tightness Testing of Piping and Equipment 207

Article 5.2 Nondestructive Examination in Lieu of Pressure Testing for Repairs

and Alterations 222

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 equip- ment 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 January 13, 2015.

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 for- mat, 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 Two 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. R. Leonard, Chair

J. Batey, Vice Chair

S. J. Rossi, Secretary

1. Becht IV, Becht Engineering Co., Inc.

2. L. Berger, PPL Generation, LLC

M. A. Boring, Kiefner & Associates, Inc.

W. Brown, Integrity Engineering Solutions

P. N. Chaku, Lummus Technology, Inc.

C. D. Cowfer, Contributing Member, Consultant

N. Y. Faransso, KBR

E. W. Hayman, Consultant

D. King, Furmanite America, Inc.

STANDARDS COMMITTEE PERSONNEL

K. Mokhtarian, Consultant

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

K. Oyamada, Delegate, The High Pressure Gas Safety Institute of Japan

T. M. Parks, The National Board of Boiler and Pressure Vessel Inspectors

J. R. Payne, JPAC, Inc.

D. T. Peters, Structural Integrity Associates

J. T. Reynolds, Intertek/Moody

W. J. Koves, Contributing Member, Pi Engineering Software, Inc.

D. A. Lang, Sr., FM Global

1. E. Lay, Hytorc

2. Michalopoulos, Contributing Member, City of Kozani, Greece

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

C. D. Rodery, BP North American Products, Inc.

J. Taagepera, Chevron Energy Technology Co.

T. Tahara, Delegate, T & T Technology

REPAIR AND TESTING SUBCOMMITTEE (PCC)

S. C. Roberts, Chair, Shell Global Standards US, Inc.

J. Taagepera, Vice Chair, Chevron Energy Technology Co.

R. J. Lucas, Secretary, The American Society of Mechanical Engineers

L. P. Antalffy, Fluor

C. Becht IV, Becht Engineering Co., Inc.

M. A. Boring, Kiefner & Associates, Inc.

J. A. Brown, Areva Transnuclear

P. N. Chaku, Lummus Technology, Inc.

H. J. Dammeyer, Patrick Engineering

N. Y. Faransso, KBR

S. J. Findlan, Shaw Power Group

1. F. Hantz, Valero Energy Corp.

2. R. Harley, GP Strategies Corp.

J. R. Jones, The Equity Engineering Group

D. M. King, Furmanite America, Inc.

W. J. Koves, Contributing Member, Pi Engineering Software, Inc.

J. A. Morton, Williams Co.

W. F. Newell, Jr., Contributing Member, Euroweld Ltd.

T. M. Parks, The National Board of Boiler and Pressure Vessel Inspectors

J. T. Reynolds, Intertek/Moody

C. D. Rodery, BP North American Products, Inc.

C. W. Rowley, The Wesley Corp.

S. C. Shah, IS GE C Hitachi Zosen Ltd.

D. B. Stewart, Contributing Member, Kansas City Deaerator Co.

T. Tahara, Contributing Member, T & T Technology

E. Upitis, Upitis & Associates, Inc.

N. Y. Faransso, Chair, KBR

C. R. Harley, Vice Chair, GP Strategies Corp.

K. Mokhtarian, Consultant

SUBGROUP ON EXAMINATION AND TESTING

J. A. Morton, Williams Co.

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

D. King, Chair, Furmanite America, Inc.

SUBGROUP ON MECHANICAL REPAIR

H. J. Dammeyer, Patrick Engineering

T. M. Parks, Vice Chair, The National Board of Boiler and Pressure Vessel Inspectors

C. Becht IV, Becht Engineering Co., Inc.

J. R. Jones, The Equity Engineering Group

C. D. Rodery, BP North American Products, Inc.

S. C. Shah, IS GE C Hitachi Zosen Ltd.

vi

C. W. Rowley, Chair, The Wesley Corp.

SUBGROUP ON NONMETALLIC REPAIR

J. Duell, Alternate, Neptune Research, Inc.

C. R. Alexander, Stress Engineering Services, Inc.

K. A. Farrag, Gas Technology Institute

S. R. Frost, Walker Technical Resources Ltd.

A. Gutkovsky, Chevron Energy Technology Co.

P. S. Hill, Furmanite America, Inc.

B. Whelan, Alternate, Furmanite America, Inc.

M. Kieba, U.S. Department of Transportation

C. J. Lazzara, Neptune Research, Inc.

M. Green, Alternate, Neptune Research, Inc.

1. M. Souza, Pipe Wrap, LLC

2. Wachholder, Consultant

R. H. Walker, Citadel Technologies

A. P. Hawkins, Alternate, Citadel Technologies

D. M. Wilson, Phillips 66

J. M. Wilson, T. D. Williamson, Inc.

F. Worth, Air Logistics Corp.

R. E. Rhea, Alternate, Air Logistics Corp.

M. A. Boring, Chair, Kiefner & Associates, Inc.

SUBGROUP ON WELDED REPAIR

S. J. Findlan, Shaw Power Group

J. Taagepera, Vice Chair, Chevron Energy Technology Co.

L. P. Antalffy, Fluor

J. A. Brown, Areva Transnuclear

P. N. Chaku, Lummus Technology, Inc.

B. F. Hantz, Valero Energy Corp.

W. F. Newell, Jr., Contributing Member, Euroweld Ltd.

J. T. Reynolds, Intertek/Moody

E. Upitis, Upitis & Associates, Inc.

vii

CORRESPONDENCE WITH THE PCC COMMITTEE

General. ASME Standards are developed and maintained with the intent to represent the consensus of concerned interests. As such, users of this Standard may interact with the Committee by requesting interpretations, proposing revisions, and attending Committee meetings. Corre- spondence should be addressed to:

Secretary, PCC Standards Committee

The American Society of Mechanical Engineers Two Park Avenue

New York, NY 10016-5990

Proposing Revisions. Revisions are made periodically to the Standard to incorporate changes that appear necessary or desirable, as demonstrated by the experience gained from the applica- tion of the Standard. Approved revisions will be published periodically.

The Committee welcomes proposals for revisions to this Standard. Such proposals should be as specific as possible, citing the paragraph number(s), the proposed wording, and a detailed description of the reasons for the proposal, including any pertinent documentation.

Interpretations. Upon request, the PCC Committee will render an interpretation of any require- ment of the Standard. Interpretations can only be rendered in response to a written request sent to the Secretary of the PCC Standards Committee.

The request for interpretation should be clear and unambiguous. It is further recommended that the inquirer submit his/her request in the following format:

Subject: Cite the applicable paragraph number(s) and the topic of the inquiry.

Edition: Cite the applicable edition of the Standard for which the interpretation is being requested.

Question: Phrase the question as a request for an interpretation of a specific requirement suitable for general understanding and use, not as a request for an approval of a proprietary design or situation. The inquirer may also include any plans or drawings that are necessary to explain the question; however, they should not contain proprietary names or information.

Requests that are not in this format may be rewritten in the appropriate format by the Committee prior to being answered, which may inadvertently change the intent of the original request.

ASME procedures provide for reconsideration of any interpretation when or if additional information that might affect an interpretation is available. Further, persons aggrieved by an interpretation may appeal to the cognizant ASME Committee or Subcommittee. ASME does not “approve,” “certify,” “rate,” or “endorse” any item, construction, proprietary device, or activity. Attending Committee Meetings. The PCC Standards Committee regularly holds meetings that are open to the public. Persons wishing to attend any meeting should contact the Secretary of

the PCC Standards Committee.

viii

ASME PCC-2–2015 SUMMARY OF CHANGES

Following approval by the ASME Post-Construction Committee and ASME, and after public review, ASME PCC-2–2015 was approved by the American National Standards Institute on January 13, 2015.

ASME PCC-2–2015 includes editorial changes, revisions, and corrections introduced in ASME PCC-2–2011, as well as the following changes identified by a margin note, (15).

(2) Original subpara. (a)(2)(c) redesignated subpara. (a)(3), original subpara. (a)(2)(c)(1) redesignated subpara. (a)(3)(a), and original subpara. (a)(2)(c)(2) redesignated subpara. (a)(3)(b)