This Standard provides methods for repair of equipment and piping within the scope of ASME Pressure Technology Codes and Standards 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 provided; administrative or policy requirements are outside of the scope of this Standard.

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5	CONTENTS
6	FOREWORD
7	PREPARATION OF TECHNICAL INQUIRIES
8	COMMITTEE ROSTER
10	CORRESPONDENCE WITH THE PCC COMMITTEE
11	SUMMARY OF CHANGES
15	PART 1 SCOPE, ORGANIZATION, AND INTENT 1 SCOPE 2 ORGANIZATION 3 INTENT
16	Table 1 Guide for the Selection of Repair Technique
19	PART 2 WELDED REPAIRS Article 2.1 Butt-Welded Insert Plates in Pressure Components 1 DESCRIPTION 2 LIMITATIONS
20	3 DESIGN Fig. 1 Flush Insert in Pipe or Tube
21	4 FABRICATION
22	Fig. 2 Flush Insert Plate (With or Without Nozzle/Manway) With Its Butt Weld Intersecting Existing Butt Weld in Shells or Heads Fig. 3 Intersecting “Doghouse” Type Insert Plate Butt Weld (With or Without Nozzle/Manway) With Shell Butt Weld in Vessel Shells and Heads
24	5 EXAMINATION OF WELDS 6 PRESSURE TESTING
25	Article 2.2 External Weld Buildup to Repair Internal Thinning 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN Fig. 1 Weld Buildup Profile
28	4 FABRICATION
29	5 EXAMINATION
30	6 TESTING 7 REFERENCES
31	Article 2.3 Seal- Welded Threaded Connections and Seal Weld Repairs 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
32	4 FABRICATION 5 EXAMINATION 6 TESTING 7 REFERENCES
33	Article 2.4 Welded Leak Box Repair 1 DESCRIPTION 2 LIMITATIONS Fig. 1 Example of a Welded Leak Box Repair of a Tee
34	3 DESIGN
35	4 FABRICATION
36	5 EXAMINATION 6 TESTING
37	Article 2.5 Welded Lip Seals
38	Article 2.6 Full Encirclement Steel Reinforcing Sleeves for Piping 1 DESCRIPTION 2 CAUTIONS AND LIMITATIONS
39	Fig. 1 Type A Sleeve
40	Fig. 2 Type B Sleeve Fig. 3 Welded Split Sleeve for Use Over a Girth Weld
41	3 DESIGN
42	4 FABRICATION Fig. 4 Type B Sleeve Fillet Weld Size for Sleeve Thickness Less Than or Equal to 1.4 Times the Carrier Pipe Thickness Fig. 5 Type B Sleeve Fillet Weld Size for Sleeve Thickness Greater Than 1.4 Times the Carrier Pipe Thickness
44	6 TESTING 7 REFERENCES
45	Article 2.7 Fillet Welded Patches With Reinforcing Plug Welds 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
46	Fig. 1 Typical Shell Repair Near Discontinuity
49	4 FABRICATION 5 EXAMINATION
50	6 TESTING 7 REFERENCES
51	Article 2.8 Alternatives to Traditional Welding Preheat 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
52	Fig. 1 Typical Residual Stresses in a Weld Fig. 2 Effect of Weld Area on Transverse Shrinkage
53	Table 1 Comparison of Specification and Actual Weld Metal Properties
54	Fig. 3 Typical Back Stepping Weld Sequence Fig. 4 Difference Between Oscillated Stringer Beads (Left) and Wide Weave Beads (Right) 4 FABRICATION
55	Fig. 5 Effect of Weld Bead Cross Section on Cracking
56	5 EXAMINATION 6 TESTING 7 REFERENCES
57	Article 2.9 Alternatives to Postweld Heat Treatment 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
58	Table 1 Summary of Postweld Heat Treatment Requirements and Potential Alternatives 4 FABRICATION 5 EXAMINATION 6 TESTING 7 REFERENCES
60	Article 2.10 In- Service Welding Onto Carbon Steel Pressure Components or Pipelines 1 DESCRIPTION 2 LIMITATIONS
61	3 DESIGN 4 FABRICATION
63	Table 1 Type and Number of Test Specimens Required for an In- Service Welding Procedure Qualification
64	5 EXAMINATION 6 TESTING 7 REFERENCES
65	Fig. 1 Heat-Affected Zone Hardness Indent Locations
66	Fig. 2 Mandrel Location Relative to the Weld Toe When Doing Face Bend Test for a Typical In-Service Fillet Weld Fig. 3 Examples of In-Service Welding Procedure Qualification Face Bend Test Samples
67	Fig. 4 Test Sample Locations for In-Service Fillet Welding Procedure Qualification Assuming Equal Spacing Around the Circumference to Obtain All the Required Test Specimens Fig. 5 Test Sample Locations for In-Service Attachment Welding Procedure Qualification Assuming Equal Spacing Around the Circumference to Obtain All the Required Test Specimens
68	Fig. 6 Test Sample Locations for In-Service Weld Metal Buildup Welding Procedure Qualification
69	Article 2.10, Mandatory Appendix I In- Service Welding Procedure/ Welder Performance Qualification Setup
72	Article 2.11 Weld Buildup, Weld Overlay, and Clad Restoration 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
73	4 FABRICATION
75	5 EXAMINATION 6 TESTING
76	7 REFERENCES
78	Article 2.12 Fillet Welded Patches 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
81	4 FABRICATION
82	5 EXAMINATION 6 TESTING 7 REFERENCES
84	Article 2.13 Threaded or Welded Plug Repairs 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN 4 FABRICATION
86	5 EXAMINATION 6 TESTING 7 REFERENCES
87	Article 2.14 Field Heat Treating of Vessels 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
90	4 FABRICATION 5 EXAMINATION
91	6 TESTING 7 REFERENCES
92	Article 2.14, Mandatory Appendix I Developing a Heat Treatment Procedure
93	Article 2.14, Mandatory Appendix II Typical Hot Box Design
95	PART 3 MECHANICAL REPAIRS Article 3.1 Replacement of Pressure Components 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN 4 FABRICATION
96	5 EXAMINATION 6 TESTING 7 REFERENCES
97	Article 3.2 Freeze Plugs 1 DESCRIPTION 2 LIMITATIONS
98	3 DESIGN
99	Fig. 1 Nitrogen Freeze Plug Assembly
100	4 FABRICATION
101	5 EXAMINATION 6 TESTING
102	Article 3.3 Damaged Threads in Tapped Holes 1 DESCRIPTION 2 LIMITATIONS
103	3 DESIGN 4 FABRICATION
104	Fig. 1 Example of Tapered Stud 5 EXAMINATION 6 TESTING 7 REFERENCES
105	Article 3.3, Mandatory Appendix I Recommended Detail for Stud Threads Modification to Prevent Damage to Threads in Tapped Holes
108	Article 3.3, Mandatory Appendix II An Illustrative Example Showing an Engineering Analysis Associated With Enlarging a Tapped Hole II- 1 EXAMPLE 1
110	II- 2 EXAMPLE 2
112	Article 3.4 Flaw Excavation and Weld Repair 1 DESCRIPTION 2 LIMITATIONS
113	Fig. 1 Excavation and Weld Repair of Surface Flaw Fig. 2 Excavation and Weld Repair of Embedded Flaw 3 DESIGN
114	Fig. 3 Grinding of Weld Flaw 4 FABRICATION 5 EXAMINATION
115	6 TESTING 7 REFERENCES
116	Article 3.4, Mandatory Appendix I Metal Removal Process I- 1 FLAPPING I- 2 GRINDING I- 3 HONING I- 4 LAPPING I- 5 MACHINING
117	I- 6 THERMAL GOUGING I- 7 BOAT SAMPLE CUTTING
118	Article 3.5 Flange Repair and Conversion 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
119	4 FABRICATION 5 EXAMINATION
120	6 TESTING 7 REFERENCES Fig. 1 Flange Dimensions
121	Article 3.6 Mechanical Clamp Repair 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
122	Fig. 1 Example of a Mechanical Clamp Fig. 2 Square Mechanical Clamp Over Drain Branch, With Sealant Injection Nozzle
124	4 FABRICATION 5 EXAMINATION 6 TESTING
125	7 REFERENCES
126	Article 3.7 Pipe Straightening or Alignment Bending 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN 4 FABRICATION
127	5 EXAMINATION 6 TESTING
128	7 REFERENCE
129	Article 3.8 Damaged Anchors in Concrete ( Postinstalled Mechanical Anchors) 1 DESCRIPTION Fig. 1 Anchors
130	2 LIMITATIONS Fig. 2 Anchor and Concrete Failure 3 DESIGN
131	Fig. 3 Column Base Anchors in Concrete Fig. 4 Weld Repair of Existing Rod 4 FABRICATION
132	Table 1 Minimum Edge Distance for Punched, Reamed, or Drilled Holes Table 2 Expansion Anchor — Illustrative Example of Typical Minimum Limits for Reference
133	Fig. 5 Wedge Anchor
134	Fig. 7 Relocation of One or Two Anchors Within an Arc (r = 1⁄2d) Fig. 8 Relocation of One or Two Anchors Within an Arc (r = d)
135	Fig. 9 Relocation of One or Two Anchors Within a Design Plate Assembly Fig. 10 Relocation of More Than Two Anchors Within a Design Plate Assembly 5 EXAMINATION 6 TESTING
136	Fig. 11 Using an Enlarged Plate 7 REFERENCES
137	Article 3.8, Mandatory Appendix I Anchors Installation Using Chemical Means ( Adhesive) I- 1 Adhesive Anchors
138	Article 3.9 Valves With Pressure Seal- Type Bonnets
139	Article 3.10 Hot Bolting
140	Article 3.11 Hot and Half Bolting Removal Procedures 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
141	4 FABRICATION
143	5 EXAMINATION 6 TESTING 7 REFERENCES
144	Article 3.12 Inspection and Repair of Shell and Tube Heat Exchangers 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
146	4 FABRICATION
147	Fig. 1 Typical Friction Fit Tapered Tube Plug
148	Fig. 2 Typical Mechanical Fit Tube Plugs Fig. 3 Typical Installation of Mechanical Fit Tube Plugs
149	Fig. 4 Sample Chart: Number of Tube Failures by Month
150	5 EXAMINATION
151	6 TESTING 7 REFERENCES
153	Article 3.12, Mandatory Appendix I Methods for Determining Minimum Number of Tubes to Inspect I- 1 Introduction
154	Table I- 1 Inspection Effectiveness Table
155	Table I- 1 Inspection Effectiveness Table ( Cont’d)
156	Article 3.12, Mandatory Appendix II Examination of Pressure Containment Components II- 1 EXAMINATION II- 2 INSPECTION II- 3 SUITABILITY
157	PART 4 NONMETALLIC AND BONDED REPAIRS Article 4.1 Nonmetallic Composite Repair Systems: High-RiskApplications 1 DESCRIPTION
158	2 LIMITATIONS 3 DESIGN
160	Table 1 Repair System Required Material and Performance Properties
161	Table 1 Repair System Required Material and Performance Properties ( Cont’d)
163	Table 2 Service Temperature Limits for Repair Systems
164	Table 3 Allowable ( Long Term) Strains for Repair Laminates ( No Allowance for Temperature Effects) Table 4 Service Factors for Repair Laminates
167	4 FABRICATION (INSTALLATION)
168	Table 5 Hold Points During Installation
169	Fig. 1 Schematic of a Repair System and Location of Defects 5 EXAMINATION
170	Table 6 Defect Type and Allowable Limits for the Composite Wrap 6 SYSTEM PRESSURE TESTING
171	7 REFERENCES
174	Article 4.1, Mandatory Appendix I Design Data Sheet
177	Article 4.1, Mandatory Appendix II Qualification Data for the Repair System II- 1 INTRODUCTION II- 2 DATA FOR REPAIR LAMINATE II- 3 DATA FOR REPAIR/ SUBSTRATE INTERFACE
178	II- 4 ADDITIONAL REQUIREMENTS FOR STRUCTURAL REPAIRS TO NONLEAKING COMPONENTS ( TYPE A DESIGN CASE) II- 5 ADDITIONAL REQUIREMENTS FOR LEAKING COMPONENTS ( TYPE B DESIGN CASE) II- 6 PERFORMANCE TESTING ( OPTIONAL QUALIFICATION TESTS)
179	Article 4.1, Mandatory Appendix III Short- Term Pipe Spool Survival Test III- 1 INTRODUCTION III- 2 METHOD III- 3 REPORT
180	Article 4.1, Mandatory Appendix IVMeasurement of y for Leaking Defect Calculation
182	Article 4.1, Mandatory Appendix V Measurement of Performance Test Data V- 1 INTRODUCTION V- 2 METHODS
183	V- 3 REPORT
184	Article 4.1, Mandatory Appendix VI Measurement of Impact Performance VI- 1 INTRODUCTION VI- 2 METHODS VI- 3 REPORT
185	Article 4.1, Mandatory Appendix VII Installer Qualification VII- 1 INTRODUCTION VII- 2 TRAINING VII- 3 TRAINING RECORDS VII- 4 REQUALIFICATION
187	Article 4.1, Mandatory Appendix VIII Installation VIII- 1 INTRODUCTION VIII- 2 SURFACE PREPARATION VIII- 3 LAMINATE LAY- UP VIII- 4 CURE VIII- 5 DOCUMENTATION
189	Article 4.1, Nonmandatory Appendix A Glossary of Terms and Acronyms A- 1 GLOSSARY OF TERMS
190	A- 2 GLOSSARY OF ACRONYMS
191	Article 4.1, Nonmandatory Appendix B Recommended Retesting for a Modified Qualified Repair System B- 1 GENERAL B- 2 MODIFIED REPAIR SYSTEM B- 3 ENGINEERING JUDGMENT
192	Table B- 1 Recommended Testing for Requalification of a Modified Qualified Repair System
193	Table B- 1 Recommended Testing for Requalification of a Modified Qualified Repair System ( Cont’d)
194	Table B- 1 Recommended Testing for Requalification of a Modified Qualified Repair System ( Cont’d)
195	Article 4.2 Nonmetallic Composite Repair Systems: Low- Risk Applications 1 DESCRIPTION 2 LIMITATIONS
196	3 DESIGN
197	Table 1 Repair System Required Material and Performance Properties
198	4 FABRICATION ( INSTALLATION) Table 2 Hold Points During Installation 5 EXAMINATION
199	Table 3 Defect Type and Allowable Limits for the Composite Repair
200	6 SYSTEM PRESSURE TESTING 7 REFERENCES
202	Article 4.2, Mandatory Appendix I Repair Data Sheet
204	Article 4.2, Mandatory Appendix II Qualification Data for Repair System II- 1 INTRODUCTION II- 2 DATA FOR REPAIR LAMINATE II- 3 DATA FOR COMPOSITE/ SUBSTRATE INTERFACE II- 4 ADDITIONAL REQUIREMENTS FOR LEAKING SUBSTRATES
205	Article 4.2, Mandatory Appendix III Validation for Repair of Leaking Component III- 1 INTRODUCTION III- 2 METHOD III- 3 REPORT
206	Article 4.2, Mandatory Appendix IV Installer Qualification IV- 1 INTRODUCTION IV- 2 TRAINING IV- 3 RECORD OF TRAINING IV- 4 QUALIFICATION PERIOD
207	Article 4.2, Mandatory Appendix V Installation V- 1 INTRODUCTION V- 2 SURFACE PREPARATION V- 3 LAMINATE LAY- UP V- 4 CURE V- 5 DOCUMENTATION
208	Article 4.2, Nonmandatory Appendix A Glossary of Terms and Acronyms A- 1 GLOSSARY OF TERMS A- 2 GLOSSARY OF ACRONYMS
209	Article 4.3 Nonmetallic Internal Lining for Pipe: Sprayed Form for Buried Pipe 1 DESCRIPTION 2 CAUTIONS AND LIMITATIONS
210	3 DESIGN
212	4 FABRICATION ( INSTALLATION)
213	5 EXAMINATION 6 TESTING 7 REFERENCES
216	Article 4.3, Mandatory Appendix I Design Considerations for Buried Pipe I- 1 WALL THICKNESS OF CIPP I- 2 DESIGN EQUATIONS I- 3 APPLIED LOADS DESIGN
218	Article 4.3, Mandatory Appendix II Inspection/ Examination and Corrective Action Requirements for CIPP II- 1 GENERAL II- 2 POLYMER MIXTURE II- 3 POLYMER THICKNESS SAMPLING II- 4 POLYMER HARDNESS II- 5 POLYMER COVERAGE II- 6 SURFACE DEFECT CORRECTIVE ACTIONS
219	II- 7 CORRECTIVE ACTION FOR AREAS OF INSUFFICIENT CURING
220	Article 4.3, Mandatory Appendix III Glossary of Terms and Acronyms III- 1 GLOSSARY OF TERMS III- 2 GLOSSARY OF ACRONYMS
221	PART 5 EXAMINATION AND TESTING Article 5.1 Pressure and Tightness Testing of Piping and Equipment 1 DESCRIPTION 2 LIMITATIONS 3 DESIGN
223	Fig. 1 Test Type Selection
224	4 FABRICATION 5 EXAMINATION 6 TESTING
229	7 REFERENCES
230	Article 5.1, Mandatory Appendix I Pressure/ Leak Testing
232	Article 5.1, Mandatory Appendix II Stored Energy Calculations for Pneumatic Pressure Test
233	Article 5.1, Mandatory Appendix III Safe Distance Calculations for Pneumatic Pressure Test III- 1 BLAST WAVE DISTANCE Table III- 1 Alternative Values for III- 2 FRAGMENT THROW DISTANCE
234	Table III- 2 Minimum Distances for Fragment Throw Considerations
235	Article 5.1, Mandatory Appendix IV Risk Evaluation Considerations for Pneumatic Pressure Test
236	Article 5.2 Nondestructive Examination in Lieu of Pressure Testing for Repairs and Alterations 1 DESCRIPTION
237	2 LIMITATIONS 3 DESIGN 4 FABRICATION ( REPAIR OR ALTERATION) 5 EXAMINATION — NONDESTRUCTIVE EXAMINATION ( NDE) 6 TESTING
238	7 REFERENCES
239	Article 5.2, Mandatory Appendix I Comparison of Selected NDE Methods
240	Table I- 1 Comparison of Selected NDE Methods
241	Table I- 1 Comparison of Selected NDE Methods ( Cont’d)

Published By	Publication Date	Number of Pages
ASME	2015	244


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Standard Title	ASME PCC-2 Repair of Pressure Equipment and Piping
Published Code	ASME
Publication Date	2015
Pages Count	244

ASME PCC 2 2015

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