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

INTENTIONALLY LEFT BLANK

ASME PCC-2–2011

(Revision of ASME PCC-2–2008)

ASME PCC-2–2011

(Revision of ASME PCC-2–2008)

Repair of Pressure Equipment and Piping

AN AMERICAN NA TIONAL S T AND ARD

Three Park Avenue • New York, NY • 10016 USA

Date of Issuance: April 28, 2011

This Standard will be revised when the Society approves the issuance of a new edition. This Standard will become effective 6 months after the Date of Issuance. There will be no addenda issued to this edition.

ASME issues written replies to inquiries concerning interpretations of technical aspects of this document. Interpretations are published on the ASME Web site under the Committee Pages at https://cstools.asme.org as they are issued.

ASME is the registered trademark of The American Society of Mechanical Engineers.

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.

Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted as government or industry endorsement of this code or standard.

ASME accepts responsibility for only those interpretations of this document issued in accordance with the established ASME procedures and policies, which precludes the issuance of interpretations by individuals.

No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise,

without the prior written permission of the publisher.

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

Copyright © 2011 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

Summary of Changes vii

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 Overlay 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 42

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

Pipelines 45

Article 2.11 Weld Buildup, Weld Overlay, and Clad Restoration 57

Article 2.12 Fillet Welded Patches 63

Article 2.13 Threaded or Welded Plug Repairs 68

Article 2.14 Field Heat Treating of Vessels 71

Part 3 Mechanical Repairs 79

Article 3.1 Replacement of Pressure Components 79

Article 3.2 Freeze Plugs 81

Article 3.3 Damaged Threads in Tapped Holes 86

Article 3.4 Flaw Excavation and Weld Repair 96

Article 3.5 Flange Repair and Conversion 102

Article 3.6 Mechanical Clamp Repair 105

Article 3.7 Pipe Straightening or Alignment Bending 109

Article 3.8 Damaged Anchors in Concrete (Postinstalled Mechanical Anchors) 112

Article 3.9 Valves With Pressure-Seal-Type Bonnets (in the course of preparation) 121

Article 3.10 Hot Bolting (in the course of preparation) 122

Article 3.11 Hot and Half Bolting Removal Procedures 123

Article 3.12 Inspection and Repair of Shell and Tube Heat Exchangers 127

Part 4 Nonmetallic and Bonded Repairs 139

Article 4.1 Nonmetallic Composite Repair Systems: High-Risk Applications 139

Article 4.2 Nonmetallic Composite Repair Systems: Low-Risk Applications 171

Article 4.3 Nonmetallic Internal Lining for Pipe: Sprayed Form for Buried Pipe 185

Part 5 Examination and Testing 197

Article 5.1 Pressure and Tightness Testing of Piping and Equipment 197

Article 5.2 Nondestructive Examination in Lieu of Pressure Testing for Repairs

and Alterations 211

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 February 11, 2011.

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 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

D. A. Lang, Sr., Chair

J. R. Sims, Jr., Vice Chair

S. J. Rossi, Secretary

G. A. Antaki, Becht Engineering Co., Inc.

J. E. Batey, The Dow Chemical Co.

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

2. L. Berger, PPL Generation, LLC

W. Brown, The Equity Engineering Group

P. N. Chaku, Lummus Technology, Inc.

C. D. Cowfer, Contributing Member, Consultant

E. W. Hayman, Consultant

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

D. A. Lang, Sr., FM Global

D. E. Lay, Hytoric

C. R. Leonard, Life Cycle Engineering

STANDARDS COMMITTEE PERSONNEL

C. C. Neely, 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.

1. T. Peters, Structural Integrity Associates

   J. T. Reynolds, Pro-Inspect, Inc.

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

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

   S. J. Rossi, The American Society of Mechanical Engineers

   C. W. Rowley, The Wesley Corp.

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

K. Mokhtarian, Consultant

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

T. Tahara, Delegate, T & T Technology

REPAIR AND TESTING SUBCOMMITTEE (PCC)

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

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

C. E. O’Brien, Secretary, The American Society of Mechanical Engineers

G. A. Antaki, Becht Engineering Co., Inc.

1. P. Antalffy, Fluor

2. A. Boring, Edison Welding Institute

J. A. Brown, AREVA NP, Inc.

P. N. Chaku, Lummus Technology, Inc.

H. J. Dammeyer, The Ohio State University

N. Y. Faransso, KBR

S. J. Findlan, Shaw Power Group

1. F. Hantz, Valero Energy Corp.

2. R. Harley, General Physics Corp.

3. M. King, Furmanite America, Inc.

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

K. Mokhtarian, Consultant

J. A. Morton, TD Williamson, Inc.

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

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

J. T. Reynolds, Pro-Inspect, Inc.

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

C. W. Rowley, The Wesley Corp.

S. C. Shah, ExxonMobil Research and Engineering Co.

D. B. Stewart, Kansas City Deaerator Co.

J. Taagepera, Chevron Energy Technology Co.

T. Tahara, Contributing Member, T & T Technology

E. Upitis, Upitis & Associates, Inc.

R. H. Walker, Citadel Technologies

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

SUBGROUP ON NONMETALLIC REPAIR

C. J. Lazzara, Neptune Research, Inc.

C. E. O’Brien, Secretary, The American Society of Mechanical Engineers

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

1. Bicerano, Bicerano and Associates Consulting, Inc.

2. A. Farrag, Gas Technology Institute

S. R. Frost, Walker Technologies, Ltd.

P. S. Hill, Glebeland

J. M. Souza, Pipe Wrap, LLC

R. H. Walker, Citadel Technologies

M. Green, Alternate, Citadel Technologies

D. M. Wilson, ConocoPhillips

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

J. A. Morton, Alternate, TD Williamson, Inc.

F. Worth, Air Logistics Corp.

vi

ASME PCC-2–2011 SUMMARY OF CHANGES

Following approval by the ASME Post Construction Committee and ASME, and after public review, ASME PCC-2–2011 was approved by the American National Standards Institute on February 11, 2011.

ASME PCC-2–2011 includes editorial changes, revisions, and corrections introduced in ASME PCC-2–2008, as well as the following changes identified by a margin note, (11).

Appendix I

77, 78 Article 2.14, Mandatory Added Appendix II

paragraphs redesignated

(3) New paras. 4.3 and 4.4 added; subsequent paragraphs redesignated

139–153 Article 4.1 Revised in its entirety 154–156 Article 4.1, Mandatory Revised

Appendix I

157–158 Article 4.1, Mandatory Revised in its entirety

Appendix II

Appendix IV

163–164 Article 4.1, Mandatory Revised Appendix V

Appendix VII

167, 168 Article 4.1, Mandatory Revised in its entirety

Appendix VIII

169, 170 Article 4.1, Mandatory Revised Appendix IX

vii

Appendix I

1. Article 4.2, Mandatory Revised Appendix II

2. Article 4.2, Mandatory Title and first sentence of III-2 revised Appendix III

3. Article 4.2, Mandatory Revised Appendix IV

viii

ASME PCC-2–2011 Part 1

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 they have 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 Standard, 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 components.

      
      

      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

1. General

   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.

2. Definitions

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

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

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

   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.

3. Administrative Requirements

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