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ASME PCC 2 2022

ASME PCC 2 2022

$98.04

ASME PCC-2 – 2022 Repair of Pressure Equipment and Piping

Published By Publication Date Number of Pages
ASME 2022 326
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This Standard provides methods for repair of equipment, piping, pipelines, and associated ancillary equipment within the scope of ASME Pressure Technology Codes and Standards 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.

PDF Catalog

PDF Pages PDF Title
4 CONTENTS
17 FOREWORD
20 CORRESPONDENCE WITH THE PCC COMMITTEE
22 ASME PCC-2–2022 SUMMARY OF CHANGES
26 PART 1 SCOPE, ORGANIZATION, AND INTENT
Article 101 Introduction
101-1 SCOPE
101-2 ORGANIZATION
101-3 INTENT
101-3.1 General
101-3.2 Acronyms and Definitions
28 101-3.3 Administrative Requirements
101-3.4 Application
101-3.5 Alternative Use
101-3.6 Articles’ Independence
101-3.7 Repair Life
101-3.8 Code References
101-3.9 Welding
101-3.10 Allowable Stress
101-3.11 Examination
101-3.12 Records
29 PART 2 WELDED REPAIRS
Article 201 Butt-Welded Insert Plates in Pressure Components
201-1 DESCRIPTION
201-1.1 General Considerations
201-1.2 Replacement of Local Areas in Pressure Vessel Shells or Pipe Walls
201-1.3 Replacement of Entire Component
201-2 LIMITATIONS
201-2.1 Part 1 of This Standard
201-2.2 Additional Considerations and Limitations
201-2.3 Loadings
201-2.4 Corrosion-Resistant Weld Overlay or Cladding
30 201-2.5 Dissimilar Metals
201-3 DESIGN
201-3.1 Construction Code
201-3.2 Materials
201-3.3 Insert Plate Thickness
201-3.4 Rectangular and Square Insert Plates
201-3.5 Flush Inserts
201-3.6 Insert Plate Size
201-3.7 Structural Stability at Cutouts
201-3.8 Insert Plates With Nozzles
31 Figures
Figure 201-3.5-1 Flush Insert in Pipe or Tube
Figure 201-3.8-1 Flush Insert Plate (With or Without Nozzle/Manway) With Its Butt Weld Intersecting Existing Butt Weld in Shells or Heads
32 201-4 FABRICATION
201-4.1 Cutting and Forming
201-4.2 Welding
Figure 201-3.8-2 Intersecting “Doghouse” Type Insert Plate Butt Weld (With or Without Nozzle/Manway) With Shell Butt Weld in Vessel Shells and Heads
33 201-4.3 Weld Spacing Between Nonintersecting Adjacent Butt Welds in Carbon Steel and Low Alloy Steel Pressure Components
201-4.4 Intersecting Butt Welds in Carbon and Low Alloy Steel Pressure Components
34 201-4.5 Postweld Heat Treatment
201-5 EXAMINATION OF WELDS
201-5.1 Insert Plate Welds
201-5.2 Finished Welded Surfaces
201-5.3 Piping
201-5.4 Additional Examination Requirements for Carbon and Low Alloy Steels
201-6 PRESSURE TESTING
201-6.1 General Considerations
201-6.2 Notch Toughness Considerations
35 201-6.3 Leak Test
201-6.4 Vessels and Piping With Insulation or Coating
36 Article 202 External Weld Buildup to Repair Internal Thinning
202-1 DESCRIPTION
202-1.1 Introduction
202-1.2 Restoration of Wall Thickness
202-2 LIMITATIONS
202-2.1 Additional Requirements
202-2.2 Cracking
202-2.3 Evaluation of Medium
202-2.4 Operation in Creep Temperature Range
202-2.5 Blocked-in Liquid-Filled Components
202-3 DESIGN
202-3.1 Buildup Design
37 Figure 202-3-1 Weld Buildup Profile
38 202-3.2 Burst Test Procedures
39 202-4 FABRICATION
202-4.1 Prerepair Inspection Requirements
202-4.2 Prerepair Surface Preparation
202-4.3 Weld Buildup Placement
202-4.4 Electrode Size and Filler
40 202-4.5 Welding Process and Techniques
202-5 EXAMINATION
202-5.1 Surface Examination
202-5.2 Buildup Thickness
202-5.3 Volumetric Examination
41 202-5.4 Surface Finish
202-6 TESTING
202-6.1 Pressure Testing
202-6.2 Volumetric Examination in Place of Pressure Testing
202-6.3 Insulation and Coating
202-7 REFERENCES
42 Article 203 Seal-Welded Threaded Connections and Seal Weld Repairs
203-1 DESCRIPTION
203-1.1 Introduction
203-1.2 Seal Welds
203-1.3 How Seal Welds Are Used
203-2 LIMITATIONS
203-2.1 Additional Requirements
203-2.2 Special Considerations Outside of Scope
203-2.3 Consideration of Hazards
203-2.4 Potential Contaminants
203-2.5 Welding and Material Considerations
203-2.6 Removal of Coatings
203-2.7 Welding Effect on Adjacent Components
43 203-3 DESIGN
203-3.1 Applicable Codes
203-3.2 Application to Existing Joints
203-3.3 Joint Reassembly
203-3.4 Two Pass Welds
203-4 FABRICATION
203-4.1 Cleaning
203-4.2 Cleaning of Joints
203-4.3 Welding Qualifications
203-4.4 Fatigue Considerations
203-4.5 Prior Seal Welded Joints
203-4.6 Welding Existing Connections Without Disassembly
203-5 EXAMINATION
203-5.1 Visual Examination
203-5.2 Magnetic Particle and Liquid Penetrant Examination
203-5.3 Acceptance Standards
203-6 TESTING
203-6.1 Initial Service Testing
44 203-6.2 Leak Testing
203-7 REFERENCES
45 Article 204 Welded Leak Box Repair
204-1 DESCRIPTION
204-2 LIMITATIONS
204-2.1 General
Figure 204-1-1 Example of a Welded Leak Box Repair of a Tee
46 204-2.2 Crack Repair
204-2.3 Qualifications
204-2.4 Safety
204-3 DESIGN
204-3.1 Materials
204-3.2 Design Life
204-3.3 Failure Modes
204-3.4 Temperature and Toughness
204-3.5 Design Conditions
204-3.6 Qualification
47 204-3.7 Corrosion Allowance
204-3.8 Design Loads
204-3.9 Transient Loads
204-3.10 Vents and Drains
204-3.11 Sound Metal
204-3.12 Sealant Pressure
204-3.13 Sealant Seepage
204-3.14 Joints
204-4 FABRICATION
204-4.1 Preparation
204-4.2 Leak Box Installation
48 204-4.3 Welding
204-4.4 In-Service Welding
204-4.5 Leaking Component
204-4.6 Heat Treatment
204-5 EXAMINATION
204-5.1 Qualifications
204-5.2 NDE Exemptions
204-5.3 Surface Examination
204-5.4 Evaluation
204-6 TESTING
204-6.1 Test Pressure
204-6.2 Test Method
204-6.3 External Pressure
49 Article 205 Weld Ring Gaskets (Welded Lip Seals)
205-1 DESCRIPTION
205-2 LIMITATIONS
205-2.1 Additional Requirements
205-2.2 Additional Considerations and Limitations
205-3 DESIGN
Figure 205-1-1 Membrane Weld Ring Gaskets
Figure 205-1-2 Weld Ring Gaskets
50 Figure 205-1-3 Hollow-Lip Weld Ring Gaskets
51 205-4 FABRICATION
205-4.1 Preparation
205-4.2 Disassembly Procedure for an Existing Weld-Ring Gasket
205-4.3 Assembly Procedure for a New Weld Ring Gasket
Figure 205-4.3-1 Centering Pin Arrangement
52 Figure 205-4.3-2 Clamped Lip Seal
Figure 205-4.3-3 Assembled Lip Seal
53 205-4.4 Procedure for Weld Ring Gasket and Membrane Weld Ring Gasket Seal Replacement
205-5 NDE EXAMINATIONS
205-5.1 Visual Examination
205-5.2 Liquid Penetrant Examination
205-5.3 Ultrasonic Examination
205-5.4 Acceptance Criteria
205-6 TESTING
205-7 REFERENCES
55 Article 206 Full Encirclement Steel Reinforcing Sleeves for Piping
206-1 DESCRIPTION
206-1.1 Full Encirclement Steel Sleeve
206-2 CAUTIONS AND LIMITATIONS
206-2.1 Additional Requirements
206-2.2 Regulations
206-2.3 Leaking Defects
206-2.4 Cyclic Operation
206-2.5 Circumferential Defects
206-2.6 Undersleeve Corrosion
206-2.7 Weld Reinforcement
56 206-2.8 Sleeve Size Requirements
206-2.9 Welding
206-2.10 Filler Material
206-3 DESIGN
206-3.1 Type A Sleeves
Figure 206-1.1.1-1 Type A Sleeve
57 206-3.2 Type B Sleeves
206-3.3 Pressure Design
206-3.4 Sleeve Dimensions
Figure 206-1.1.2-1 Type B Sleeve
58 206-3.5 Type B Sleeve Fillet Welds
206-3.6 External Pressure
206-3.7 External Damage
206-3.8 Cyclic Operation
206-3.9 Restraint of Pipe Bulging
206-3.10 Type A Sleeve Filler Material
206-3.11 Differential Thermal Expansion
206-4 FABRICATION
206-4.1 Installation
Figure 206-2.7-1 Welded Split Sleeve for Use Over a Girth Weld
59 206-4.2 Filler Materials
206-4.3 Leaking Defects
206-4.4 Welds
Figure 206-3.5-1 Type B Sleeve Fillet Weld Size for Sleeve Thickness Less Than or Equal to 1.4 Times the Carrier Pipe Thickness
Figure 206-3.5-2 Type B Sleeve Fillet Weld Size for Sleeve Thickness Greater Than 1.4 Times the Carrier Pipe Thickness
60 206-4.5 Reduced Pressure
206-4.6 In-Service Welding
206-4.7 Welding Procedures and Welder Qualifications
206-5 EXAMINATION
206-5.1 Visual Examination
206-5.2 Type A Sleeves
206-5.3 Type B Sleeves
206-5.4 In-Process Examination
206-5.5 Nondestructive Examination
206-6 TESTING
61 206-7 REFERENCES
62 Article 207 Fillet Welded Patches With Reinforcing Plug Welds
207-1 DESCRIPTION
207-2 LIMITATIONS
207-3 DESIGN
207-3.1 General
63 Figure 207-1-1 Typical Shell Repair Near Discontinuity
64 207-3.2 Internal Pressure Loads
65 207-3.3 Structural Discontinuity Evaluation
207-3.4 Allowable Load on Perimeter Fillet Weld
207-3.5 Allowable Loads on Plug Welds
66 207-3.6 Cold Forming Limits
207-4 FABRICATION
67 207-5 EXAMINATION
207-6 TESTING
207-7 REFERENCES
68 Article 208 Alternatives to Traditional Welding Preheat
208-1 DESCRIPTION
208-2 LIMITATIONS
208-2.1 General
208-2.2 Prohibited Reduction
208-2.3 Inappropriate Cases
208-2.4 Limited Access
208-2.5 Welding
208-3 DESIGN
208-3.1 Groove Geometry
69 208-3.2 Welding Process
208-3.3 Welding Consumables
208-3.4 Carbon Equivalent
Figure 208-3.1-1 Typical Residual Stresses in a Weld
Figure 208-3.1-2 Effect of Weld Area on Transverse Shrinkage
70 208-3.5 Cracking Parameter (Pcm)
208-3.6 Controlled Deposition Welding
208-4 FABRICATION
208-4.1 Cleanliness
208-4.2 Welding Technique
Tables
Table 208-3.3-1 Comparison of Specification and Actual Weld Metal Properties
71 208-4.3 Peening
208-4.4 Minimizing Cracking
208-4.5 Preheat Methods
208-4.6 Preheat Monitoring
208-5 EXAMINATION
Figure 208-4.2-1 Typical Back Stepping Weld Sequence
Figure 208-4.2-2 Difference Between Oscillated Stringer Beads (Left) and Wide Weave Beads (Right)
72 208-6 TESTING
208-7 REFERENCES
Figure 208-4.4-1 Effect of Weld Bead Cross Section on Cracking
74 Article 209 Alternatives to Postweld Heat Treatment
209-1 DESCRIPTION
209-1.1 General Considerations
209-1.2 Factors Affecting Selection
209-2 LIMITATIONS
209-2.1 Post-Construction Code
209-2.2 Methods
209-2.3 Suitability Tests
209-2.4 Resistance to Service Conditions
209-2.5 Residual Stress Reduction
209-2.6 Altering Material Properties
75 209-3 DESIGN
209-3.1 Dissimilar Metal Welds
209-3.2 Procedures
209-4 FABRICATION
209-4.1 Application of Elevated Preheat
209-4.2 Alternative Welding Methods
209-4.3 Requiring Additional Methods
209-5 EXAMINATION
Table 209-4.1-1 Summary of Postweld Heat Treatment Requirements and Potential Alternatives
76 209-6 TESTING
209-7 REFERENCES
77 Article 210 In-Service Welding Onto Carbon Steel Pressure Components or Pipelines
210-1 DESCRIPTION
78 210-2 LIMITATIONS
210-2.1 Additional Requirements
210-2.2 Piping and Pipeline Modifications
210-2.3 Pressure Components or Pipeline Material
210-2.4 Pressure Components or Pipeline Contents
210-2.5 Operating Pressure
210-2.6 Operating Flow
210-2.7 Postweld Heat Treatment (PWHT)
210-3 DESIGN
210-3.1 In-Service Fillet Weld Procedure
210-3.2 In-Service Attachment Weld Procedure
210-3.3 In-Service Weld Metal Buildup Procedure
79 210-4 FABRICATION
210-4.1 Welding Procedure Qualification: Welding
210-4.1.1 In-Service Welding Essential Variables.
80 210-4.2 Weld Procedure Qualification: Testing
210-4.2.1 Destructive Test Methods.
Table 210-4.2.1-1 Type and Number of Test Specimens Required for an In-Service Welding Procedure Qualification
81 Figure 210-4.2.1.2-1 Heat-Affected Zone Hardness Indent Locations
82 Figure 210-4.2.1.4-1 Mandrel Location Relative to the Weld Toe When Doing Face Bend Test for a Typical In-Service Fillet Weld
Figure 210-4.2.1.4-2 Examples of In-Service Welding Procedure Qualification Face Bend Test Samples
83 210-4.2.2 Sample Location.
210-4.3 Welder Performance Qualification
210-5 EXAMINATION
210-5.1 NDE Method
210-5.2 Examination Time
210-6 TESTING
210-7 REFERENCES
84 Figure 210-4.2.2-1 Test Sample Locations for In-Service Fillet Welding Procedure Qualification Assuming Equal Spacing Around the Circumference to Obtain All the Required Test Specimens
85 Figure 210-4.2.2-2 Test Sample Locations for In-Service Attachment Welding Procedure Qualification Assuming Equal Spacing Around the Circumference to Obtain All the Required Test Specimens
86 Figure 210-4.2.2-3 Test Sample Locations for In-Service Weld Metal Buildup Welding Procedure Qualification
87 Mandatory Appendix 210-I In-Service Welding Procedure/Welder Performance Qualification Setup
Figure 210-I-1 Procedure and Welder Qualification Test Assembly for an In-Service Fillet Weld
88 Figure 210-I-2 Procedure and Welder Qualification Test Assembly for an In-Service Attachment Weld
89 Article 211 Weld Buildup, Weld Overlay, and Clad Restoration
211-1 DESCRIPTION
211-1.1 Introduction
211-1.2 Scope
211-1.3 Damaged Base Metal
211-1.4 Damaged Weld Overlay and Cladding
211-1.5 Definitions
211-2 LIMITATIONS
211-2.1 Additional Requirements
211-2.2 Base Metal Condition
211-3 DESIGN
211-3.1 Cause of Damage
211-3.2 Number of Weld Layers
211-3.3 Weld Thickness
211-3.4 Multiple-Layer Welding
90 211-3.5 Base Metal Restoration
211-3.6 Corrosion Protection
211-3.7 Design Calculations
211-3.8 Other Considerations
211-4 FABRICATION
211-4.1 Surface Preparation
211-4.2 Welding Procedure Qualification
211-4.3 Weld Overlay
211-4.4 Back Cladding
211-4.5 Special Considerations for Low Alloy Steels
91 211-4.6 Surface Profile
211-4.7 Heat Treatment
Figure 211-4.4.1-1 Weld Seam With Back Cladding
92 211-5 EXAMINATION
211-5.1 General
211-5.2 Copper Sulfate Solution Testing
211-5.3 Liquid Penetrant Examination of Weld Overlay and Back Cladding
211-6 TESTING
211-6.1 Chemical Analysis
93 211-6.2 Chemical Composition of Austenitic Stainless Steel Weld Deposits
211-6.3 Ferrite Testing of Austenitic Stainless Steel Weld Deposits
211-6.4 Calibration of Magnetic Ferrite Testing Gages
211-6.5 Ferricyanide Testing of Ni–Cu (Alloy 400) and Cu–Ni Alloys
211-6.6 Hydrostatic Testing
211-7 REFERENCES
95 Article 212 Fillet Welded Patches
212-1 DESCRIPTION
212-2 LIMITATIONS
212-3 DESIGN
212-3.1 General
96 Figure 212-1-1 Typical Shell Repair Near Discontinuity
97 212-3.2 Internal Pressure Loads
212-3.3 Structural Discontinuity Evaluation
98 212-3.4 Allowable Load on Perimeter Fillet Weld
212-3.5 Cold Forming Limits
212-4 FABRICATION
99 212-5 EXAMINATION
212-6 TESTING
212-7 REFERENCES
101 Article 213 Threaded or Welded Plug Repairs
213-1 DESCRIPTION
213-2 LIMITATIONS
213-2.1 General
213-2.2 Repairs
213-2.3 Corrosion
213-3 DESIGN
213-3.1 Design Review
213-3.2 Material Properties
213-3.3 Opening Reinforcement
213-3.4 Strength Requirements
213-3.5 Strength and Corrosion Consequences
213-3.6 Material Removal
213-3.7 Finish Dimensions
213-4 FABRICATION
213-4.1 Flaw Location
102 213-4.2 Flaw Removal
213-4.3 Plug Fabrication
213-4.4 Lubricants
213-4.5 Plug Insertion
213-4.6 Seal or Fillet Welding
213-5 EXAMINATION
213-5.1 Flaw Removal Verification
213-5.2 Surface Examination
213-5.3 Documentation
213-6 TESTING
213-7 REFERENCES
103 Figure 213-3.1-1 Typical Plug Arrangement
104 Article 214 Field Heat Treating of Vessels
214-1 DESCRIPTION
214-1.1 Introduction
214-1.2 Scope
214-1.3 Application
214-2 LIMITATIONS
214-2.1 Additional Requirements
214-2.2 Work Location
214-2.3 Codes and Standards
214-3 DESIGN
214-3.1 Methods
105 214-3.2 Thermal Expansion
106 214-3.3 Materials Considerations
214-3.4 Structural Considerations
107 214-4 FABRICATION
214-4.1 Heat Treat Contractor’s Procedure
214-4.2 Instrumentation of Heat Treatment
214-4.3 Special Considerations
108 214-4.4 Monitoring
214-4.5 Record Retention
214-5 EXAMINATION
214-5.1 Vessel
214-5.2 Structures
214-5.3 Piping
214-5.4 Instrumentation and Electrical
214-5.5 Insulation
214-6 TESTING
109 214-7 REFERENCES
110 Mandatory Appendix 214-I Developing a Heat Treatment Procedure
111 Mandatory Appendix 214-II Typical Hot Box Design
112 Figure 214-II-1 Typical Hot Box Design
113 Article 215 Repair Welding Considerations for Cr–Mo Steel Pressure Vessels
215-1 DESCRIPTION
215-1.1 Scope
215-1.2 Application
215-1.3 Design Temperature
215-1.4 Applicable Materials
215-2 LIMITATIONS
215-3 DESIGN
215-3.1 Feasibility Study of Repair Welding
215-3.2 Consideration of In-Service Degradation
215-3.3 Examples of Damage
215-3.4 Development of Weld Repair Procedures
114 215-3.5 Repair Welding Methods Applicable to Cr–Mo Vessels
215-3.6 Welding and Preheat
215-4 FABRICATION
215-4.1 Weld Repair Procedures
215-4.2 Preparation for Welding
215-4.3 Welding Conditions
215-4.4 Preheating and Post-Heating
215-4.5 De-Embrittlement Heat Treatment
215-4.6 Dehydrogenation Heat Treatment
215-4.7 Postweld Heat Treatment
215-5 EXAMINATION
115 215-6 PRESSURE TESTING
215-7 REFERENCES
117 Table 215-1.2-1 Cr–Mo Steels Applicable to This Article
118 Figure 215-3.1-1 Standard Steps in Repair Welding
119 Table 215-3.2-1 Typical In-Service Degradation
Table 215-3.2-2 Typical Considerations for Weld Repair of In-Service Degradation
120 Figure 215-3.3-1 Examples of Damage Common to Cr–Mo Pressure Vessels
121 Figure 215-3.4-1 Flowchart for the Selection of Repair Welding Methods
Table 215-3.5-1 Repair Methods Applicable to Cr–Mo Vessels
122 Table 215-4.1-1 Repair Approach Sequence
Table 215-4.4-1 Typical Preheat and Interpass Temperatures
123 Table 215-4.5-1 De-Embrittlement Heat Treatment
124 Article 216 Welded Hot Taps in Pressure Equipment or Pipelines
216-1 DESCRIPTION
216-1.1 Hot Tapping Connections
216-1.2 Hot Tap Drilling Machine
216-1.3 Hot Tapping Activities
125 216-2 LIMITATIONS
216-2.1 Additional Requirements
216-2.2 Nonwelded Fittings
216-2.3 Welding Concerns
216-2.4 Conditions and Applications for Which Hot Tapping Is Not Recommended
216-2.5 Conditions for Which Hot Tapping Requires Special Precautions
Figure 216-1.2-1 Typical Hot Tapping Setup
126 216-2.6 Additional Requirements
216-2.7 Additional Requirements
216-3 DESIGN
216-3.1 Hot Tap Checklist
216-3.2 Hot Tap Fittings
127 216-3.3 Branch Design Requirements
216-3.4 Full Encirclement Sleeves Design Requirements
216-3.5 Hot Tap Length and Size
216-3.6 Hot Tap Location
216-3.7 Hot Tap Orientation
128 216-3.8 Coupon Retention and Contamination During Hot Tapping
216-3.9 Hot Tap Valve
216-3.10 Flow Rate and Minimum Liquid Level in Pressure Equipment for Hot Tap
216-3.11 Wall Thickness to Prevent Burn-Through During Welding
129 216-3.12 Maximum Allowable Internal Pressure for Welding of Hot Tap Fittings
216-3.13 Maximum Permissible External Pressure
130 216-3.14 Pressure Equipment Stresses From Applied Loads on Hot Tap Nozzles
216-3.15 Piping Supports
216-4 FABRICATION
216-4.1 Welding
131 216-4.2 Execution of the Hot Tap
216-5 EXAMINATION
216-5.1 Pre-Hot Tap Examination
132 216-5.2 Hot Tap Fitting Field Welds
216-5.3 Hot Tap Fitting Shop Fabrication Welds
216-6 PRESSURE TESTING
216-6.1 Cutting Equipment
216-6.2 Hot Tap Valve
216-6.3 Hot Tap Fitting — General Considerations
216-6.4 Pressure Test Medium
133 216-6.5 Hydrostatic Testing of Hot Tap Fittings
216-6.6 Pneumatic Test of Hot Tap Fittings
216-7 REFERENCES
216-7.1 Referenced Codes and Standards
216-7.2 Related Codes and Standards
134 216-7.3 Related Technical Publications
135 Nonmandatory Appendix 216-A Glossary of Acronyms
216-A-1 GLOSSARY OF ACRONYMS
216-A-1.1 Organizations
216-A-1.2 Terms
136 Article 217 Seal Welding of Leaking Water Systems
217-1 DESCRIPTION
217-2 LIMITATIONS
217-2.1 Additional Requirements
217-2.2 Welding Process
217-2.3 Material
217-2.4 Application
217-3 DESIGN
217-3.1 Repair Limitations
217-3.2 Requirements
217-4 FABRICATION
217-4.1 Weld Procedure Qualification
217-4.2 Examination Prior to Seal Welding
137 217-4.3 Surface Preparation
217-4.4 Peening
217-4.5 Cleaning
217-4.6 Seal Welding
217-5 EXAMINATION OF THE SEAL WELD
217-6 PRESSURE TESTING
217-7 REFERENCES
138 PART 3 MECHANICAL REPAIRS
Article 301 Replacement of Pressure Components
301-1 DESCRIPTION
301-2 LIMITATIONS
301-3 DESIGN
301-3.1 Mitigation
301-3.2 Engineering Evaluation
301-3.3 Design Code
301-3.4 Modifications
301-4 FABRICATION
301-4.1 Safety
301-4.2 Welding
301-4.3 Tie-in Joint
301-4.4 Bolted Joint
139 301-5 EXAMINATION
301-5.1 Criteria
301-5.2 Mechanical Tie-in
301-6 TESTING
301-6.1 Criteria
301-6.2 Alternative
301-6.3 Design Change Monitoring
301-7 REFERENCES
140 Article 302 Freeze Plugs
302-1 DESCRIPTION
302-1.1 Technique
302-1.2 Application
302-1.3 Risk Assessment
302-1.4 Basis
302-2 LIMITATIONS
302-2.1 Additional Requirements
302-2.2 Safety Considerations
302-2.3 Freeze Point
141 302-2.4 Hydrocarbon Precautions
302-2.5 Light Ends
302-2.6 Impact Loading
302-2.7 Flow
302-2.8 Initial Fluid Temperature
302-2.9 Adjacent Flows
302-3 DESIGN
302-3.1 Pipe Materials
302-3.2 Material Property Changes
302-3.3 Pressure
302-3.4 Strength
302-3.5 Location
302-3.6 Liquid Nitrogen Freeze Plugs
142 302-3.7 Carbon Dioxide Freeze Plugs
302-4 FABRICATION
302-4.1 Procedures
302-4.2 Compatibility
302-4.3 Coolant Supply
302-4.4 Insulation and Coatings
143 Figure 302-3.6.3-1 Nitrogen Freeze Plug Assembly
144 302-4.5 Environment
302-4.6 Closed Systems
302-4.7 Related Equipment
302-4.8 Installation
302-4.9 Monitoring Time Frame
302-4.10 Plug Verification
302-4.11 Leakage
302-4.12 Welding
302-4.13 Duration
302-4.14 Testing
302-4.15 Return to Service
302-4.16 Thawing
302-5 EXAMINATION
302-5.1 Visual Inspection
302-5.2 Nondestructive Examination
302-5.3 Evaluation
145 302-6 TESTING
302-6.1 Unknown Fluid Properties
302-6.2 Freeze Point Test
302-6.3 Temperature Monitor Calibration
302-6.4 Oxygen Monitor Calibration
146 Article 303 Damaged Threads in Tapped Holes
303-1 DESCRIPTION
303-1.1 Introduction
303-1.2 Methods of Repair — Alternatives
303-1.3 Repair Methods Not Covered
303-2 LIMITATIONS
303-2.1 Additional Requirements
303-2.2 Retapping Existing Holes
303-2.3 Design Adequacy of Enlarging Stud Holes
303-2.4 Repair of Cracks
303-2.5 Welding and Material Considerations
147 303-2.6 Helical Coil Thread Inserts
303-3 DESIGN
303-3.1 Applicable Codes
303-3.2 Thread Modification
303-3.3 Enlargement of Existing Holes
303-3.4 Hole Enlargement Implications on Design
303-3.5 Design of Helical Coil Thread Inserts
303-4 FABRICATION
303-4.1 Hole Depth of Penetration
303-4.2 Hole Preparation Before Welding
148 303-4.3 Welding Procedures and Qualifications
303-4.4 Welding and Material Considerations
303-4.5 Flange Refinishing
303-4.6 Installation of Helical Coil Thread Inserts
303-4.7 Thread Galling and Lubrication
303-5 EXAMINATION
303-5.1 Visual Examination
303-5.2 Need for Additional NDE
303-5.3 Examination Procedures
303-6 TESTING
303-7 REFERENCES
Figure 303-3.3.3-1 Example of Tapered Stud
150 Mandatory Appendix 303-I Recommended Detail for Stud Threads Modification to Prevent Damage to Threads in Tapped Holes
151 Figure 303-I-1 Inch Thread Series (U.S. Customary Units)
152 Figure 303-I-2 Inch Thread Series (SI Units)
153 Figure 303-I-3 Metric Thread Series (SI Units)
154 Mandatory Appendix 303-II An Illustrative Example Showing an Engineering Analysis Associated With Enlarging a Tapped Hole
303-II-1 EXAMPLE 1
157 303-II-2 EXAMPLE 2
158 Article 304 Flaw Excavation and Weld Repair
304-1 DESCRIPTION
304-2 LIMITATIONS
304-2.1 Additional Requirements
304-2.2 Grinding
304-2.3 Machining
304-2.4 Honing
304-2.5 Flapping
159 304-2.6 Thermal Gouging
304-2.7 Generalized Damage
304-3 DESIGN
304-3.1 Excavation Without Weld Deposit
304-3.2 Weld Deposition
Figure 304-3.1-1 Excavation and Weld Repair of Surface Flaw
Figure 304-3.1-2 Excavation and Weld Repair of Embedded Flaw
160 304-3.3 Mechanical Excavation
304-4 FABRICATION
304-4.1 Repair Steps
304-4.2 Special Fixtures
Figure 304-3.1-3 Grinding of Weld Flaw
161 304-5 EXAMINATION
304-5.1 Critical Service
304-5.2 Volumetric Examination
304-5.3 Additional Examinations
304-6 TESTING
304-6.1 Applicability
304-6.2 Test Method
304-6.3 Exemption
304-7 REFERENCES
162 Mandatory Appendix 304-I Metal Removal Process
304-I-1 FLAPPING
304-I-2 GRINDING
304-I-3 HONING
304-I-4 LAPPING
304-I-5 MACHINING
163 304-I-6 THERMAL GOUGING
304-I-7 BOAT SAMPLE CUTTING
164 Figure 304-I-7-1 Boat Sample
165 Article 305 Flange Repair and Conversion
305-1 DESCRIPTION
305-1.1 Introduction
305-1.2 Work Location
305-2 LIMITATIONS
305-2.1 Additional Requirements
305-2.2 Recurrence of Damage
305-2.3 Remaining Thickness
305-2.4 Residual Stress
305-3 DESIGN
305-3.1 Raised Face
305-3.2 Thickness Evaluation
305-3.3 Finish and Flatness
166 305-4 FABRICATION
305-4.1 Repair Without Welding
305-4.2 Repair by Welding
305-4.3 Postweld Heat Treatment
305-4.4 Machining
305-4.5 Conversion of Flange Facing From Ring-Type Joint to Raised Face
167 305-5 EXAMINATION
305-5.1 Gasket Surface
305-5.2 Nondestructive Examination
305-5.3 Dimensions
305-6 TESTING
305-7 REFERENCES
305-7.1 Related Standards
Figure 305-4.5.2-1 Flange Dimensions
168 Article 306 Mechanical Clamp Repair
306-1 DESCRIPTION
306-2 LIMITATIONS
306-2.1 General
306-2.2 Applicability
306-2.3 Qualifications
306-2.4 Safety
Figure 306-1-1 Example of a Mechanical Clamp
169 306-2.5 Precautions
306-3 DESIGN
306-3.1 Materials
306-3.2 Design Life
306-3.3 Failure Modes
Figure 306-1-2 Square Mechanical Clamp Over Drain Branch, With Sealant Injection Nozzle
170 306-3.4 Temperature and Toughness
306-3.5 Design Conditions
306-3.6 Qualification
306-3.7 Corrosion Allowance
306-3.8 Design Loads
306-3.9 Transient Loads
306-3.10 Vents and Drains
306-3.11 Sound Metal
306-3.12 Sealant Pressure
306-3.13 Sealant Seepage
171 306-3.14 Joints
306-4 FABRICATION
306-4.1 Preparation
306-4.2 Leak Box Installation
306-4.3 Qualification
306-4.4 In-Service Installation
306-4.5 Leak Stoppage
306-4.6 Welding
306-5 EXAMINATION
306-5.1 Applicability
306-5.2 Visual Examination
306-5.3 Evaluation
306-6 TESTING
306-6.1 Applicability
306-6.2 Test Method
306-7 REFERENCES
172 Article 307 Pipe Straightening or Alignment Bending
307-1 DESCRIPTION
307-2 LIMITATIONS
307-2.1 General
307-2.2 Buckling Prevention
307-2.3 Materials
307-2.4 Linings and Coatings
307-2.5 Hazards Review
307-3 DESIGN
307-3.1 Preventing Recurrence
307-3.2 Analysis
307-3.3 Load and Deformation Limits
307-3.4 Residual Chemicals
173 307-4 FABRICATION
307-4.1 Methods
307-4.2 Surface Protection
307-4.3 Hot or Cold Bending
307-4.4 Heat Treatment
307-5 EXAMINATION
307-5.1 Applicability
174 307-5.2 Weld Examination
307-6 TESTING
307-6.1 Applicability
307-6.2 Special Consideration
307-6.3 Alternative
307-7 REFERENCE
175 Article 308 Damaged Anchors in Concrete (Postinstalled Mechanical Anchors)
308-1 DESCRIPTION
308-1.1 Anchor Uses
308-1.2 Intent
308-1.3 Types of Mechanical Anchors
308-1.4 Illustrations
308-1.5 Anchor Failure
308-1.6 Postinstalled Mechanical Anchor
176 308-1.7 Column Base Mechanical Anchor
308-2 LIMITATIONS
308-2.1 Additional Requirements
308-2.2 Considerations
308-3 DESIGN
308-3.1 Original Anchor Assembly
Figure 308-1.3-1 Anchors
Figure 308-1.5-1 Anchor and Concrete Failure
177 308-3.2 Design Considerations
308-4 FABRICATION
308-4.1 Weld Repair of Existing Rods
308-4.2 Repair of Existing Rods With Extensions
308-4.3 Replacement
Figure 308-1.7-1 Column Base Anchors in Concrete
178 308-4.4 Abandon in Place
308-4.5 Tolerance on Expansion Anchor Location
Figure 308-4.1-1 Weld Repair of Existing Rod
179 308-4.6 Tolerance for Anchors With 8d Embedment
Table 308-4.3-1 Minimum Edge Distance for Punched, Reamed, or Drilled Holes
Table 308-4.3-2 Expansion Anchor — Illustrative Example of Typical Minimum Limits for Reference
180 Figure 308-4.3.1-1 Wedge Anchor
Figure 308-4.3.2-1 Sleeve Anchor
Figure 308-4.5.1.1-1 Relocation of One or Two Anchors Within an Arc (r = 1⁄2d)
181 308-5 EXAMINATION
Figure 308-4.5.1.1-2 Relocation of One or Two Anchors Within an Arc (r = d)
Figure 308-4.6.1-1 Relocation of One or Two Anchors Within a Design Plate Assembly
Figure 308-4.6.2-1 Relocation of More Than Two Anchors Within a Design Plate Assembly
182 308-6 TESTING
308-7 REFERENCES
Figure 308-4.6.3-1 Using an Enlarged Plate
183 Mandatory Appendix 308-I Anchors Installation Using Chemical Means (Adhesive)
308-I-1 Adhesive Anchors
184 Article 309 Valves With Pressure Seal-Type Bonnets
185 Article 310 Hot Bolting
186 Article 311 Hot and Half Bolting Removal Procedures
311-1 DESCRIPTION
311-1.1 Introduction
311-1.2 Hot Bolting
311-1.3 Half Bolting
311-1.4 Definition of Bolt
311-2 LIMITATIONS
311-2.1 Additional Requirements
311-2.2 Risks Associated With Hot and Half Bolting
311-2.3 Procedures and Safe Work Practices
187 311-3 DESIGN
311-3.1 Engineering and Risk Analysis
311-3.2 Minimum Number of Flange Bolts
311-3.3 Determining Maximum Pressures When Conducting Hot/Half Bolting
311-3.4 Maximum Pressure/Hot Bolting
311-3.5 Maximum Pressure/Half Bolting
311-3.6 Tapped Holes — Use of Hot Bolting
188 311-4 FABRICATION
311-4.1 Preparation
311-4.2 Execution
189 311-5 EXAMINATION
311-5.1 Examination for Workmanship and Leakage
311-5.2 Examination of Bolts for Proper Material Specification
311-6 TESTING
311-7 REFERENCES
190 Article 312 Inspection and Repair of Shell and Tube Heat Exchangers
312-1 DESCRIPTION
312-2 LIMITATIONS
312-2.1 General
312-2.2 Exclusions
312-3 DESIGN
312-3.1 Existing Conditions
312-3.2 General
191 312-3.3 Tubes and Tube Bundles
312-3.4 Tubesheet
192 312-3.5 Tube-to-Tubesheet Joints
312-3.6 Bimetallic Shell-to-Tubesheet Welds
312-3.7 Shell, Channel, or Other Pressure-Retaining Components
312-4 FABRICATION
312-4.1 General Considerations
193 312-4.2 Tubeside Repair by Plugging
Figure 312-4.2-1 Typical Friction Fit Tapered Tube Plug
194 312-4.3 Tubeside Repair by Sleeving Tubes
Figure 312-4.2-2 Typical Mechanical Fit Tube Plugs
Figure 312-4.2-3 Typical Installation of Mechanical Fit Tube Plugs
195 312-4.4 Tubeside Repair by Ferrule Installation
312-4.5 Tubeside Repair by Pulling Tubes
312-4.6 Tubeside Repair by Replacement
312-4.7 Tubesheet Repair
Figure 312-4.2-4 Sample Chart: Number of Tube Failures by Month
196 312-4.8 Tube-to-Tubesheet Joint Repair
312-4.9 Repair of Pressure Containment Components
312-5 EXAMINATION
312-5.1 Examination of Tubes and Tube Bundle
197 312-5.2 Examination of Tube-to-Tubesheet Repair
312-5.3 Examination of Tubesheet Repair
312-5.4 Examination of Pressure Containment Components Repairs
312-6 TESTING
312-7 REFERENCES
199 Mandatory Appendix 312-I Methods for Determining Minimum Number of Tubes to Inspect
312-I-1 Introduction
200 Table 312-I-1.3-1 Inspection Effectiveness Table
202 Mandatory Appendix 312-II Examination of Pressure Containment Components
312-II-1 EXAMINATION
312-II-2 INSPECTION
312-II-3 SUITABILITY
205 Figure 313-4.1-1 Crimp Block on Pipe
206 Figure 313-4.1-2 Crimp With Injection Arrangement
Figure 313-4.1-3 Crimp Clamp in Position (Right) and Sealant Injection Box (Left)
208 PART 4 NONMETALLIC AND BONDED REPAIRS
Article 401 Nonmetallic Composite Repair Systems: High-Risk Applications
401-1 DESCRIPTION
401-1.1 Scope
401-1.2 Applicability
209 401-1.3 Risk Assessment
401-1.4 Repair Life
401-1.5 Defect Assessment
401-2 LIMITATIONS
401-2.1 Additional Requirements
401-2.2 Qualification of Repair System
401-2.3 Installation
401-3 DESIGN
401-3.1 Symbols
210 401-3.2 Repair System Qualification
211 Table 401-3.2-1 Repair System Required Material and Performance Properties
213 401-3.3 Required Data
401-3.4 Design Methodology
214 Table 401-3.4.2-1 Service Temperature Limits for Repair Systems
215 Table 401-3.4.4-1 Allowable (Long-Term) Strains for Repair Laminates (No Allowance for Temperature Effects)
216 Table 401-3.4.5-1 Service Factors for Repair Laminates
218 401-3.5 Approval
401-4 FABRICATION (INSTALLATION)
401-4.1 General
401-4.2 Materials of Construction
219 401-4.3 Storage Conditions
401-4.4 Method Statements
401-4.5 Installer Qualifications
401-4.6 Installation Guidance
220 401-4.7 Live Repairs
401-5 EXAMINATION
401-5.1 Introduction
401-5.2 Defects Within the Repair System
401-5.3 Repair of Defects Within the Repair System
401-5.4 Inspection Methods
Table 401-4.6-1 Hold Points During Installation
221 401-5.5 Repair System Replacement Strategy
401-6 SYSTEM PRESSURE TESTING
401-7 REFERENCES
401-7.1 Referenced Codes and Standards
Figure 401-5.1-1 Schematic of a Repair System and Location of Defects
222 Table 401-5.2-1 Defect Type and Allowable Limits for the Composite Wrap
224 401-7.2 Related Codes and Standards
226 Mandatory Appendix 401-I Design Data Sheet
227 Forms
Component Repair Data Sheet
229 Mandatory Appendix 401-II Qualification Data for the Repair System
230 Mandatory Appendix 401-III Short-Term Pipe Spool Survival Test
231 Mandatory Appendix 401-IV Measurement of γ for Leaking Defect Calculation
232 Mandatory Appendix 401-V Measurement of Performance Test Data
233 Mandatory Appendix 401-VI Measurement of Impact Performance
234 Mandatory Appendix 401-VII Installer Qualification
401-VII-1 INTRODUCTION
401-VII-2 TRAINING
401-VII-3 TRAINING RECORDS
235 401-VII-4 REQUALIFICATION
236 Mandatory Appendix 401-VIII Installation
401-VIII-1 INTRODUCTION
401-VIII-2 SURFACE PREPARATION
401-VIII-3 LAMINATE LAY-UP
401-VIII-4 CURE
401-VIII-5 DOCUMENTATION
238 Nonmandatory Appendix 401-A Glossary of Terms and Acronyms
401-A-1 GLOSSARY OF TERMS
239 401-A-2 GLOSSARY OF ACRONYMS
240 Nonmandatory Appendix 401-B Recommended Retesting for a Modified Qualified Repair System
241 Article 402 Nonmetallic Composite Repair Systems: Low-Risk Applications
402-1 DESCRIPTION
402-1.1 Scope
402-1.2 Applicability
402-1.3 Risk Assessment
242 402-1.4 Repair Life
402-2 LIMITATIONS
402-2.1 Additional Requirements
402-2.2 Loading
402-3 DESIGN
402-3.1 Symbols
402-3.2 Repair System Qualification Data
402-3.3 Additional Required Data
402-3.4 Calculations
243 Table 402-3.2-1 Repair System Required Material and Performance Properties
244 402-3.5 Approval
402-4 FABRICATION (INSTALLATION)
402-4.1 Storage Conditions
402-4.2 Materials of Construction
402-4.3 Installer Qualifications
402-4.4 Installation Guidance
245 402-4.5 Live Repairs
402-5 EXAMINATION
402-5.1 Introduction
402-5.2 Defects Within the Repair System
402-5.3 Inspection Methods
402-5.4 Repair of Defects Within the Repair System
402-6 SYSTEM PRESSURE TESTING
Table 402-4.4-1 Hold Points During Installation
246 Table 402-5.2-1 Defect Type and Allowable Limits for the Composite Repair
247 402-7 REFERENCES
402-7.1 Referenced Codes and Standards
248 402-7.2 Related Codes and Standards
249 Mandatory Appendix 402-I Repair Data Sheet
250 Repair Data Sheet
251 Mandatory Appendix 402-II Qualification Data for Repair System
252 Mandatory Appendix 402-III Validation for Repair of Leaking Component
253 Mandatory Appendix 402-IV Installer Qualification
402-IV-1 INTRODUCTION
402-IV-2 TRAINING
402-IV-2.1 Coursework (Installer)
402-IV-2.2 Coursework (Supervisor/Trainer)
402-IV-2.3 Installer-Specific Qualification
402-IV-3 TRAINING RECORDS
402-IV-4 QUALIFICATION PERIOD
254 Mandatory Appendix 402-V Installation
402-V-1 INTRODUCTION
402-V-2 SURFACE PREPARATION
402-V-3 LAMINATE LAY-UP
402-V-4 CURE
402-V-5 DOCUMENTATION
256 Nonmandatory Appendix 402-A Glossary of Terms and Acronyms
402-A-1 GLOSSARY OF TERMS
257 402-A-2 GLOSSARY OF ACRONYMS
258 Article 403 Nonmetallic Internal Lining for Pipe: Sprayed Form for Buried Pipe
403-1 DESCRIPTION
403-1.1 Background
403-1.2 Advantages
403-1.3 Disadvantages
403-2 CAUTIONS AND LIMITATIONS
403-2.1 General
403-2.2 Application Temperature Limitations
403-2.3 Operating Temperature Limitations
403-2.4 Application Humidity Limitations
259 403-2.5 Application Surface Limitations
403-2.6 Application Curing Limitations
403-3 DESIGN
403-3.1 General Design Considerations
Figure 403-1.1-1 Structural Liner in Raw Water System
260 403-3.2 Types of Sprayed Form
403-3.3 Piping Degradation Cases
403-3.4 Material Considerations
403-3.5 Material Property Determination
261 403-3.6 Specific Design Requirements
403-4 FABRICATION (INSTALLATION)
403-4.1 Host Pipe Examination and Preparation
262 403-4.2 Polymer Mixing
403-4.3 Materials of Construction
403-4.4 Polymer Application
403-5 EXAMINATION
403-5.1 Test Sample Retrieval
403-5.2 Material Testing
403-5.3 CIPP-Installed Geometry Verification
403-5.4 Documentation of CIPP As-Installed Condition
263 403-5.5 Monitoring Plans
403-6 TESTING
403-6.1 Isolable Pipe
403-6.2 Nonisolable Pipe
403-7 REFERENCES
403-7.1 Referenced Codes and Standards
264 403-7.2 Related Codes and Standards
265 403-7.3 Related Technical Publications
266 Mandatory Appendix 403-I Design Considerations for Buried Pipe
403-I-1 WALL THICKNESS OF CIPP
403-I-2 DESIGN EQUATIONS
267 403-I-3 APPLIED LOADS DESIGN
268 Mandatory Appendix 403-II Inspection/Examination and Corrective Action Requirements for CIPP
403-II-1 GENERAL
403-II-2 POLYMER MIXTURE
403-II-3 POLYMER THICKNESS SAMPLING
403-II-4 POLYMER HARDNESS
403-II-5 POLYMER COVERAGE
403-II-6 SURFACE DEFECT CORRECTIVE ACTIONS
269 403-II-7 CORRECTIVE ACTION FOR AREAS OF INSUFFICIENT CURING
270 Mandatory Appendix 403-III Glossary of Terms and Acronyms
403-III-1 GLOSSARY OF TERMS
403-III-2 GLOSSARY OF ACRONYMS
271 Article 404 Nonmetallic Internal Lining for Pipe: High-Risk Buried Pipe
272 Article 405 Qualification of Nonmetallic Composite Repair Systems
405-1 DESCRIPTION
405-1.1 Scope
405-1.2 Definition of Repair System
405-1.3 Materials Allowed
405-1.4 Types of Repair Systems
405-2 LIMITATIONS
405-3 DESIGN
405-3.1 Symbols
273 405-3.2 Repair System Qualification Process
405-3.3 Test Methods
405-3.4 Basic Material Documentation
405-3.5 Repair System Qualification Data
405-3.6 Specific Repair System Requirements
274 Table 405-3.3-1 Repair System Required Material and Performance Properties
275 405-3.7 Requalification
276 405-4 FABRICATION (INSTALLATION)
405-5 EXAMINATION
405-6 SYSTEM PRESSURE TESTING
405-7 REFERENCES
405-7.1 Referenced Codes and Standards
277 405-7.2 Related Codes and Standards
278 Mandatory Appendix 405-I Qualification Data Sheet
405-I-1 REPAIR SYSTEM DETAILS
405-I-2 TEST DATA
279 Test Data
280 Mandatory Appendix 405-II Basic Qualification Testing
405-II-1 INTRODUCTION
405-II-2 DATA FOR REPAIR LAMINATE
405-II-3 DATA FOR REPAIR/SUBSTRATE INTERFACE
281 Figure 405-II-2-1 Test Specimen Geometry
282 Mandatory Appendix 405-III Short-Term Pipe Spool Survival Test
405-III-1 INTRODUCTION
405-III-2 METHOD
Figure 405-III-2-1 Defect Dimensions
283 405-III-3 REPORT
284 Mandatory Appendix 405-IV Measurement of γ for Leaking Defect Calculation
405-IV-1 INTRODUCTION
405-IV-2 METHOD
405-IV-3 CALCULATION OF γ
285 405-IV-4 REPORT
Table 405-IV-3-1 Student’s tv Value for Double-Sided 0.025 Level of Significance
286 Mandatory Appendix 405-V Measurement of Performance Test Data
405-V-1 INTRODUCTION
405-V-2 METHODS
287 405-V-3 REPORT
288 Mandatory Appendix 405-VI Measurement of Impact Performance
405-VI-1 INTRODUCTION
405-VI-2 METHODS
405-VI-3 REPORT
289 Mandatory Appendix 405-VII Validation for Repair Technique of Leaking Component
405-VII-1 INTRODUCTION
405-VII-2 METHOD
405-VII-3 REPORT
290 Nonmandatory Appendix 405-A Glossary of Terms and Acronyms
405-A-1 GLOSSARY OF TERMS
291 405-A-2 GLOSSARY OF ACRONYMS
292 Nonmandatory Appendix 405-B Retesting Requirements for a Modified Qualified Repair System
405-B-1 GENERAL
405-B-2 MODIFIED REPAIR SYSTEM
405-B-3 ENGINEERING JUDGMENT
293 Table 405-B-1-1 Recommended Testing for Requalification of a Modified Qualified Repair System
295 PART 5 EXAMINATION AND TESTING
Article 501 Pressure and Tightness Testing of Piping and Equipment
501-1 DESCRIPTION
501-2 LIMITATIONS
501-3 DESIGN
501-3.1 Definitions
501-3.2 Reasons for Pressure and Tightness Testing
296 501-3.3 Test Type Selection
501-3.4 Pressure Test — General
501-3.5 Documentation
501-4 FABRICATION
501-5 EXAMINATION
297 Figure 501-3.3-1 Test Type Selection
298 501-6 TESTING
501-6.1 Hydrostatic Pressure Test of Pressure Vessels or Piping Systems
300 501-6.2 Pneumatic Pressure Test of Pressure Vessels or Piping
302 501-6.3 Tightness Test
303 501-7 REFERENCES
304 Mandatory Appendix 501-I Pressure/Leak Testing
305 Test Record
306 Mandatory Appendix 501-II Stored Energy Calculations for Pneumatic Pressure Test
501-II-1 GENERAL
307 Mandatory Appendix 501-III Safe Distance Calculations for Pneumatic Pressure Test
501-III-1 BLAST WAVE DISTANCE
501-III-2 FRAGMENT THROW DISTANCE
Table 501-III-1-1 Alternative Values for Rscaled
308 Table 501-III-2-1 Minimum Distances for Fragment Throw Considerations
309 Mandatory Appendix 501-IV Risk Evaluation Considerations for Pneumatic Pressure Test
501-IV-1 INTRODUCTION
501-IV-2 PNEUMATIC TEST RISK CONSIDERATIONS
501-IV-3 PIPING SYSTEM VOLUME CONSIDERATIONS
310 Figure 501-IV-3-1 A Schematic Diagram of a Pipeline Burst, Showing the Flow of Gas Within the Pipes
311 Article 502 Nondestructive Examination in Lieu of Pressure Testing for Repairs and Alterations
502-1 DESCRIPTION
502-1.1 Background
502-1.2 Application
502-1.3 Pressure Testing
502-1.4 Nondestructive Examination (NDE)
502-1.5 Pressure Test
502-1.6 NDE Methods
312 502-1.7 Brittle Fracture Risk
502-2 LIMITATIONS
502-2.1 Alternative Requirements: Part 1 of ASME PCC-2
502-2.2 Repaired or Altered Pressure Equipment
502-2.3 Examples Where Pressure Test May Be Inadvisable
502-2.4 Repairs and Alterations for Which Pressure Testing Is Not Normally Required (ANSI/NB-23)
502-3 DESIGN
502-4 FABRICATION (REPAIR OR ALTERATION)
502-5 EXAMINATION — NONDESTRUCTIVE EXAMINATION (NDE)
313 502-6 TESTING
502-7 REFERENCES
314 Mandatory Appendix 502-I Comparison of Selected NDE Methods
315 Table 502-I-1 Comparison of Selected NDE Methods
317 Article 503 Test Devices for Localized Pressure or Tightness Testing of Welded Repairs
503-1 DESCRIPTION
503-1.1 General
503-1.2 Definitions
503-2 LIMITATIONS
503-2.1 Part 1 of This Standard
503-2.2 Additional Considerations and Limitations
318 503-3 DESIGN
503-3.1 Type I — Internal Plug With Unconnected External Blind Flange
Figure 503-1.1.2-1 Hydrotest Device Types for Piping or Nozzles
319 Figure 503-1.1.3-1 Hydrotest Device Types for Nozzles or Branch Connections
320 503-3.2 Type II — Internal Double-Ended Plug With External Means of Applying Bolt Load to the Flange
503-3.3 Type III — Internal Plug Connected to an External Blind Flange
503-3.4 Type IV — Internal Double-Ended Plug With No Assembly Load on Flange
503-4 FABRICATION
Table 503-3-1 Device Type Selection Guidance
321 503-4.1 Type I – Internal Plug With Unconnected External Blind Flange
503-4.2 Type II – Internal Double-Ended Plug With External Means of Applying Bolt Load to the Flange
503-4.3 Type III – Internal Plug Connected to an External Blind Flange
503-4.4 Type IV – Internal Double-Ended Plug With No Assembly Load on Flange
503-4.5 Types A, B, and C – Hydrotest Device Types for Nozzle Welds or Piping Branch Connections
Figure 503-4-1 Hydrotest Device Seal Location
322 503-5 EXAMINATION
503-5.1 Examination Prior to Initiation of the Hydrotest
503-5.2 Examination During the Hydrotest
503-5.3 Examination Following Completion of the Hydrotest
503-6 TESTING
Figure 503-4.1-1 Type I Hydrotest Device With Lanyard
Figure 503-4.1-2 Type I Hydrotest Device Without Lanyard
323 503-7 REFERENCES
Figure 503-4.1-3 Type I Typical Installations
324 Figure 503-4.2-1 Location of Split Ring Flange
Figure 503-4.4-1 Type IV Device

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