POST CONSTRUCTION COMMITTEE - Hybrid Petroleumhybridpetroleum.com/pdfs/Presentacion ASME PPC-2-2… · · 2014-06-16-PPC-3 Published in its first edition in 2008, Planning Inspectorate

POST CONSTRUCTION COMMITTEE ASME (PCC-2) REPAIR AND TESTING

Contents of this presentation:• Scope, organization, and intent ASME PCC Organization• Subcommittee ASME PCC-2• Integrating Standards for Inspection and Service Repairs• The Four Groups Repair Types• Organization and standardized formats repair and testing• Highlights of existing articles in the first edition• Highlights of the articles in its second edition (soon to be published)• Work In Progress• Summary, Comments

THREE SUBCOMMITTEES OF PCC

• Subcommittee assemblies bolted joints:-PCC-1 Published in 2000, Guide for the pressure limits in Flanged jointswith screws, next issue, forthcoming.

• Subcommittee on tests and repairs:-PPC-2 Published in 2006 and 2009, Repair of Equipment and PressurePiping.

• Subcommittee on Planning Inspectorate:-PPC-3 Published in its first edition in 2008, Planning Inspectorate

POST CONSTRUCTION COMMITTEE ASME (PCC) REPAIR AND TESTING

• Subcommittee on repair and testing (PCC-2) was established in 1999• PCC-2 developed a standardized norm to describe and document

"Good practice of engineering generally recognized and accepted" forthe repair of equipment and pressure piping

• In order to develop these best practices PCC-2 uses the consensusprocess and vote on ANSI, involving numerous companies andindividuals experienced

• All articles of repair and testing are relatively generic, and can beadapted to the specific conditions of faults and defects that must berepaired in your workplace


Current and planned editions:• First edition of PCC-2, published in 2006 with 17 articles Repair and

Testing• Second edition forthcoming publication with 10 more articles Repair

and Testing• A third edition is being planned with 10 or 12 articles more of repair and

testing, which is in preparation• Practices PCC-2 not meant to be taken by the jurisdictions directly,

such practices are referenced to existing codes such as API-510, API-570, API-653 and NBIC


In the grand scheme of Codes and Standards Service, Where to apply thePCC-2 practices?1. These do not cover the following:

• Requirements for new constructions• Planning and Preparing for Inspections• Risk studies for planning inspections• Methods and techniques of in-service inspections• Evaluation of failures and studies fitness for service (FFS)

2. Each of the above issues are covered by other codes or differentrules, which are integrated into PCC-2 to help the user to maintain themechanical integrity of pressure equipment

CODES AND STANDARDS FOR NEW CONSTRUCTION

CODES AND STANDARDS OF RISK ANALYSIS AND PLANNING

INSPECTION

INSPECTION FINDINGS

SUCCESSFUL?

REPAIR OR REPLACEMENT?

CODES AND STANDARDS FOR

THE STUDY OF FITNESS FOR

SERVICE

CODES AND STANDARDS FOR

REPAIR OR REPLACEMENT FOR EACH INSPECTION

IN SERVICE

No

Inspect

Results

YesNo

Yes

Yes

Results

No

INTEGRATION OF CODES AND STANDARDS INSPECTION AND REPAIR IN SERVICE


Scope Standard PCC-2:• Covers all equipment that are in the scope of API and ASME relating to

Pressure Equipment including:‒ Pipes and components (such as valves, flanges and

arrangements)‒ Heaters / boilers‒ Pressure vessels (including heat exchangers)‒ Storage Tanks

• It is not limited to equipment that were built according to ASME code• Covers repairs after the equipment is in service• Repairs during construction are covered by the new construction

codes, assuming the case


Organization Standard PCC-2:• Part I covers scope, organization, and intent of the standard and its

application to all articles Repair and Testing• Each different type of repair is covered by a specific article• All articles are organized into four separate sections:

‒ Part 2: Welded repairs‒ Part 3: Mechanical repairs‒ Part 4: Non-metallic and bonded repairs‒ Part 5: Examination and Testing


Standard/Format Scheme for each article :

• Description of repair• Limitations and precautions associated with the repair• Problems of design / manufacturing associated with repair• Examination practice and testing, followed by repair• Additional references


Administrative requirements :• The administrative requirements are the provisions of a code, standard

or regulation other than the associated with the technical requirements,such as:‒ Inspection reports‒ Maintenance points‒ Documentation Requirements‒ Approval and registration requirements, etc.

• PCC-2 does not contain this type of administrative requirements, whichare left to the responsibility of the service codes and the jurisdiction towhich the rule refers repair

• PCC-2 focuses on technical issues for repair and testing, for example,guidance on recommended methods for the realization of repairs


Temporary Repairs Vs Permanent Repairs:• The repair standard does not classify repairs, whether temporary or

permanent• It is the responsibility of the owner-user to determine the expected life

of each repair• Technical considerations affecting service life are described in

individual repair articles to allow the user the appropriate determinationof inspection intervals and replacement

• The life of a repair may depend on many factors, including:‒ Repair design‒ Number and magnitude of temperature and pressure cycles‒ Time at different load conditions‒ Environment (operating and external)‒ Consequence of failure and risk tolerance


Articles Welded Repairs:• Butt-Welded Insert Plates in Pressure Components • External Weld Overlay to Repair Internal Thinning • Seal-Welded Threaded Connections and Seal Weld Repairs• Welded Leak Box • Welded Lip Seals (in the course of preparation)• Full Encirclement Steel Reinforcing Sleeves for Piping• Fillet Welded Patches With Reinforcing Plug Welds• Alternatives to Traditional Welding • Alternatives to Postweld Heat Treatment• In-Service Welding Onto Carbon Steel Pressure Components or• Pipelines • Weld Buildup, Weld Overlay, and Clad Restoration• Fillet Welded • Threaded or Welded Plug Repairs


Mechanical Repairs Articles:• Replacement of Pressure Components • Freeze Plugs • Damaged Threads in Tapped • Flaw Excavation and Weld Repair • Flange Repair and Conversion • Mechanical Clamp Repair • Pipe Straightening or Alignment Bending • Damaged Anchors in Concrete (Postinstalled Mechanical Anchors)• Valves With Pressure-Seal-Type Bonnets (in the course of preparation)• Hot Bolting (in the course of preparation) • Hot and Half Bolting Removal Procedures • Inspection and Repair of Shell and Tube Heat Exchangers


Articles of Non-Metallic Repairs:• Nonmetallic Composite Repair Systems for Pipelines and Pipework:• High-Risk Applications • Nonmetallic Composite Repair Systems for Pipelines and Pipework:• Low-Risk Applications • Nonmetallic Internal Lining for Pipe: Sprayed Form for Buried Pipe


Articles of Tests and Examination:• The examination and test requirements for each specific type of repair

are covered in the last section of each article• However, two items of examination and generic tests include:

‒ Pressure and Tightness Testing of Piping and Equipment ‒ Nondestructive Examination in Lieu of Pressure Testing for Repairs‒ and Alterations

PART 2: WELD REPAIR (5 EXISTING)

• Article 2.1 Butt-Welded Insert Plates in Pressure Components • Article 2.2 External Weld Overlay to Repair Internal Thinning• Article 2.3 Seal-Welded Threaded Connections and Seal Weld Repairs• Article 2.4 Welded Leak Box • Article 2.5 Welded Lip Seals (in the course of preparation)• Article 2.6 Full Encirclement Steel Reinforcing Sleeves for Piping

Article 2.1 Butt-Welded Insert Plates in Pressure Component

• Replacement of pressure boundary material with an insert plateattached by full penetration butt welds

• Cover plate portions (incomplete plates, sections, or components)• It can be applied to external or internal pressure• Substitutions of Plates may include nozzle• The limited size just enough to meet the tolerances

Article 2.2 External Weld Overlay to Repair Internal Thinning

• Covers repairs due to Inner thinning of the components throughexternal weld overlay

• Excludes repair of components with cracks• In some cases, these repairs can be performed with the equipment or

the line in operation• Used more in the industry of power generation than in the oil industry

Article 2.3 Seal-Welded Threaded Connections and Seal Weld Repairs

• Covers the requirements for sealing threaded connection with welding,where a higher degree of filling is required

• It can be used for piping systems in service or the original construction• It includes many cautions and limitations to advise the user

Article 2.4 Welded Leak Box

• Covers the conditioning of the site to be used for repairs / welds on site• It can repair pipes, flanges, valves, fittings, etc.• Includes a variety of shapes and sizes• It can be installed with or without sealant pumping on box• It can be designed for the loading capacity, or simply a structural

reinforcement• Excludes connections with bolts or clamps, which is covered in

mechanical repairs

Article 2.6 Full Encirclement Steel Reinforcing Sleeves for Piping

• Type A sleeve:- Only used for reinforcement, not to hold the pressure- For leaks and defects do not grow

• Type B sleeve:- Circumferentially welded to the pipe to support the pipe- To suppress leakage and provide to pipe high load capacity and pressure

PART 3: MECHANICAL REPAIRS (8 EXISTING)

• Article 3.1 Replacement of Pressure Components • Article 3.2 Freeze Plugs • Article 3.3 Damaged Threads in Tapped Holes • Article 3.4 Flaw Excavation and Weld Repair • Article 3.5 Flange Repair and Conversion • Article 3.6 Mechanical Clamp Repair • Article 3.7 Pipe Straightening or Alignment Bending • Article 3.8 Damaged Anchors in Concrete (Postinstalled Mechanical Anchors)

Article 3.1 Replacement of Pressure Components

• Covers the replacement of pressure equipment and piping components orsubassemblies

• It can be replenished by a new equipment or any modification to the existing

Article 3.2 Freeze Plugs

• A technique used to make a type of cryogenic insulation, freezing the outside ofthe pipe wall and the fluid in this to create a plug

• Usually CO2 and liquid nitrogen are used as freezing agents• It can be used in a variety of liquids• He has experience with pressures up to 2500 PSI• Includes a large number of safety tips• New: Expanded to include duplex SS materials

Article 3.3 Damaged Threads in Tapped Holes

• Includes options: :

‒ Drilling and tapping the existing stud holes to a larger size, and replacingthe existing size fastener with one sized accordingly

‒ Drilling and tapping the existing stud holes to a larger size, for the purposeof installing helical-coil threaded inserts

‒ Filling the existing stud holes with weld metal, redrilling, and retapping theholes

Article 3.4 Flaw Excavation and Weld Repair

• It covers all the flaws on surfaces that exceed tolerances code• Failures can be suppressed by welding or excavation or leave them as they are

if is appropriate• Includes, polishing, grinding, machining, heat treatment, etc.

Article 3.5 Flange Repair and Conversion

• Includes re-finishing, repair and overhaul of the flange faces:‒ Mechanical repair of imperfections‒ Restoration of material due to corrosion or other damage‒ Changing the face of the flange or allow the use of different gaskets‒ Includes machining with or without accumulation of weld metal

Article 3.6 Mechanical Clamp Repair

• Divide the screwed components into leak components or components damagedreinforced

• Elements standardized from catalog or design• With or without injectable sealant• Reinforced to withstand the pressure built• They may be structural (proof pressure) and nonstructural (for reinforcement)

Article 3.7 Pipe Straightening or Alignment Bending

• Establishes requirements and precautions for the correction of a bent metalpipe bending with hot or cold

• It can be used to improve the adjustment in process or misalignment• Does not include those systems that are composed of mechanical joints

(flanges, threaded joints, expansion joints, compression fittings, etc.)

Article 3.8 Damaged Anchors in Concrete (Postinstalled Mechanical

Anchors)• Covers repair of anchors buried in the concrete foundations of the columns• Includes anchors installed by mechanical or chemical means• Includes extending existing anchor bolts

PART 4: NONMETALLIC AND BONDED REPAIRS

(3 EXISTING)

• Article 4.1 Nonmetallic Composite Repair Systems for Pipelines and Pipework:High-Risk Applications

• Article 4.2 Nonmetallic Composite Repair Systems for Pipelines and Pipework:Low-Risk Applications

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

Article 4.1 Nonmetallic Composite Repair Systems for Pipelines and Pipework: High-

Risk Applications

• Repair System include glass, aramid, or carbon fiber reinforcement in athermoset polymer

• Addresses the repair of pipework and pipelines in accordance with ASME B31• They can be used for metallic and non-metallic systems• Can be repaired:‒ External corrosion when component integrity is compromised‒ Dents, scratches, wear and rub‒ Cracks with adequate preparation‒ Corrosion, internal erosion that may or may not cause leakage‒ Leaks‒ Manufacturing and workmanship defects

Article 4.2 Nonmetallic Composite Repair Systems for Pipelines and Pipework: Low-

Risk Applications

• Repair systems consisting of fiber reinforcements in resin matrices• Intended for low-risk pipes• Can be repaired:‒ External corrosion damage‒ Erosion / internal corrosion‒ Leaks‒ Manufacturing and workmanship defects• Eliminated B31.4 as an example or reference to reflect low risk applications• Clarify qualification data and test validation requirements

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

• Covers thermoset polymers sprayed as protective coating or structural ofburied pipes

• Can provide the structural strength, chemical, abrasion resistance, barrierleakage and flow improved

• Limited to buried pipelines• More effective in diameters greater than 24 inches• It can be applied manually or with any spray equipment• Minimum temperature restrictions

PART 5: Examination and Testing

• Article 5.1 Pressure and Tightness Testing of Piping and Equipment

Artículo 5.1 Pressure and Tightness Testing of Piping and Equipment

• Provides recommended practices for determining:‒ Test Type‒ Pressure test‒ Test Procedure• Provides an overview of the types of test applications, benefits and limitations• Provides guidelines to follow for hydrostatic testing, pneumatic, watertightness

and leakage• Not address the isolation of parts of the system for testing purposes or vacuum

testing• Explains 5 specific reasons for which these tests should be performed

TEN NEW ITEMS IN PCC-2, 2nd EDITION

• PART 1: Scope, Organization, and Intent• PART 2: Welded Repairs (7 new)• PART 3: Mechanical Repairs (2 new)• PART 4: Nonmetallic and Bonded Repairs• PART 5: Examination and Testing (1 new)

PART 2: Welded Repairs (7 new)

• Article 2.7 Fillet Welded Patches With Reinforcing Plug Welds• Article 2.8 Alternatives to Traditional Welding Preheat• Article 2.9 Alternatives to Postweld Heat Treatment• Article 2.10 In-Service Welding Onto Carbon Steel Pressure Components or

Pipelines• Article 2.11 Weld Buildup, Weld Overlay, and Clad Restoration• Article 2.12 Fillet Welded Patches• Article 2.13 Threaded or Welded Plug Repairs

Article 2.7 Fillet Welded Patches With Reinforcing Plug Welds

• Covers all aspects of Article 2.12 and also provides guidelines on howto design and manufacture some pressure loads transferred to the weldreinforcement included with the patch

Article 2.8 Alternatives to Traditional Welding Preheat

• Provides guidelines for alternatives preheating when may be inadmissible orimpractical to apply preheating

• Six alternative strategies are discussed along with their advantages, limitationsand problems of manpower:

‒ Change geometries‒ Change of welding processes and techniques‒ Using different welding consumables‒ Evaluation of the carbon equivalent‒ Evaluation of parameters of cracks‒ Realization of the weld deposit in a controlled way• Analyzed alternatives where preheating is needed, effective methods for

implementation and control of preheating

Article 2.9 Alternatives to Postweld Heat Treatment

• Provides guidelines for alternative heat treatments post-weld, when performingthis process is unacceptable or impractical

• The main alternatives include high preheating techniques and weld techniquesdeposit controlled

• They may be special considerations required for troubles due to failuremechanisms such as cracking stress, hydrogen cracking, or loss of tenacity

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

• Provides guidelines and precautions for welding on components in service• The two main problems in welding that need to be approached are burning and

hydrogen cracking• Three types of welding services include: Fillet welds, weld joints and weld metal

accumulation• Covers eleven variables in the WPS of welding service, including: the type of

welding, cooling rate, carbon equivalence, supplies, heat input, current, preheatand reheat

• Recommendations for welding procedure qualification in service include thetypes of destructive tests, macro-cutting tests and hardness testing

Article 2.11 Weld Buildup, Weld Overlay, and Clad Restoration

• As the name says are provided the guidelines for the accumulation of weld(base metal loss), overlap welding (loss of corrosion resistance) and coatingrestoration, when it happened some thinning

• It covers a number of special considerations for welding: number of weldinglayers to be applied, effective depth resistant to corrosion, surface preparation,new siding, welding low alloy steels, heat treatment, chemical testing inoverlaps and non destructive testing

Article 2.12 Fillet Welded Patches

• Covers the requirements for repair by patching with fillet weld (including metallicjacketed pipe) where permitted by service codes like API 510 and API 570

• Provides guidelines for repairs fillet weld patches in high-and low-temperatureservices

• Provides formulas for designing patches fillet weld various types and contours,including allowable loads on the perimeter of fillet welds

• The manufacturing guide includes: edge preparation, shapes, tolerances, WPS,WQR, ventilation of patch plate during welding, non-destructive testing and leaktest

Article 2.13 Threaded or Welded Plug Repairs

• Provides guidance on the restoration of the integrity of a component byinserting a solid or threaded cap, where a fault has been removed, includingwelding seal to ensure the tightness, if desired

• The design and manufacturing guide includes: reinforcement opening, materialproperties, removal of material, dimensions, defect elimination, seal welding,examination and testing

PART 3: Mechanical Repairs (2 new)

• Article 3.11 Hot and Half Bolting Removal Procedures• Article 3.12 Inspection and Repair of Shell and Tube Heat Exchangers

Article 3.11 Hot and Half Bolting Removal Procedures

• Covers the issues involved for the sequential removal and replacement of thebolts that belong to boards that are still in service (removal hot) and issuesrelated to the removal of all other bolts during depressurization system

• Focus on risk assessment and safe work practices in the use of eitherprocedure sets, including over 25 issues that may affect the risk assessment

• Guidance is also provided in the implementation phase including: verification oftenacity, string, cleaning, lubrication, reference readings, tighten and cut boltsseized

Article 3.12 Inspection and Repair of Shell and Tube Heat Exchangers

• Covers techniques of inspection, testing and Repair for the shell side and tubeside of a heat exchanger, including: the tube bundle, tubesheet, casing andother components

• A guide to the problems related to the design to be evaluated is given, based onthe results of the inspection

• Covers different considerations to repair leaks in the tubes and tube sheetsincluding: rolling, tamponade, sealing or brazing, and various methods ofrepairing pipes and casing

• Several methods of tubular cleaning are discussed including water jet cleaning,chemical cleaning and abrasive blasting

• Advantages and disadvantages of several common types of pipe inspectionsuch as IRIS, EC, RFEC, PSEC, MFL, VT, RT, along with an appendix thatprovides guidance on how to select the minimum number of tubes to beinspected

PART 5: Examination and Testing (1 new)

• Article 5.2 Nondestructive Examination in Lieu of Pressure Testing for Repairsand Alterations

Article 5.3 Nondestructive Examination in Lieu of Pressure Testing for Repairs and Alterations

• Covers issues to consider (advantages and disadvantages) when a pressuretest is not practical or non-destructive testing can demonstrate greater efficacyand safety pressure testing

• Complements Article 5.1 which includes guidance on safe and effectivemethods of pressure testing

• Start with the most valid reasons why it is advisable to do the pressure test first,but still with a number of real examples of when a pressure test is inadvisableor impractical

• Includes a general chart of 14 nondestructive testing methods that can replacethe pressure test, listing what each detected including its advantages anddisadvantages

• It also includes a list of typical repairs or alterations that usually do not requirepressure testing

Final Comments• PCC-2 is a standard that describes and documents the good engineering

practices for the repair of pressure equipment and piping after they have beenput into service

• The first edition (2006) includes 17 items• The second edition (2009) includes 10 articles• Work continues with 10-12 additional items to be included in the next edition• All items are designed and referrals to service codes current inspection and

repair• Ideas for additional items and companies repair procedures are needed and

welcome• Committee members willing to attend meetings, prepare more articles and

reviews about the votes, are needed and welcome

Documents

POST CONSTRUCTION COMMITTEE - Hybrid Petroleumhybridpetroleum.com/pdfs/Presentacion ASME PPC-2-2… · · 2014-06-16-PPC-3 Published in its first edition in 2008, Planning Inspectorate