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 Date of Issuance: December 31, 2018

The next edition of this Standard is scheduled for publication in 2022.

ASME issues written replies to inquiries concerning interpretations of technical aspects of this Standard. Periodically certain actions of the ASME
PCC Committees may be published as Cases. Cases and interpretations are published on the ASME website under the Committee Pages at
http://cstools.asme.org/ as they are issued.

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Errata to codes and standards may be posted on the ASME website under the Committee Pages to provide corrections to incorrectly published
items, or to correct typographical or grammatical errors in codes and standards. Such errata shall be used on the date posted.

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"Publication Information” section.

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

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This code or standard was developed under procedures accredited as meeting the criteria for American National Standards. The Standards
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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
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document, and does not undertake to insure anyone utilizing a standard against liability for infringement of any applicable letters patent, nor
assume 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.
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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,

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in an electronic retrieval system or otherwise,

without the prior written permission of the publisher.
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The American Society of Mechanical Engineers

Two Park Avenue, New York, NY 10016-5990
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Copyright © 2018 by
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THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS

All rights reserved
Printed in U.S.A.

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 CONTENTS

Foreword .......................................................................................................................................................... xv
Committee Roster ........................................................................................................................................... xvi
Correspondence With the PCC Committee ................................................................................................... xvhi
Summary of Changes ...................................................................................................................................... xx
Part 1 Scope, Organization, and Intent ............................................................... 1
Article 101 Introduction ............................................................................................... 1

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101-1 Scope........................................................................................................ 1

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101-2 Organization ............................................................................................. 1
101-3 Intent ......................................................................................................... 1
Part 2 Welded Repairs ........................................................................................ 3

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Article 201 Butt-Welded Insert Plates in Pressure Components ................................. 3
201-1 Description ................................................................................................ 3
201-2 Limitations................................................................................................. 3

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201-3 Design....................................................................................................... 4
201-4 Fabrication ................................................................................................ 6
201-5 Examination of Welds ............................................................................... 8
201- 6
Article 202 O
Pressure Testing ....................................................................................... 8
External Weld Buildup to Repair Internal Thinning .................................. 10
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202- 1 Description ............................................................................................... 10
202-2 Limitations................................................................................................ 10
202-3 Design...................................................................................................... 10
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202-4 Fabrication ............................................................................................... 13

202-5 Examination ............................................................................................. 14
202-6 Testing ..................................................................................................... 15
202- 7 References .............................................................................................. 15
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Article 203 Seal-Welded Threaded Connections and Seal Weld Repairs ........................................................ 16
203- 1 Description ............................................................................................... 16
203-2 Limitations................................................................................................ 16
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203-3 Design...................................................................................................... 17
203-4 Fabrication ............................................................................................... 17
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203-5 Examination ............................................................................................. 17

203-6 Testing ..................................................................................................... 17
203- 7 References .............................................................................................. 18
Article 204 Welded Leak Box Repair……………………………………………………………………………….…..19
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204- 1 Description ............................................................................................... 19

204-2 Limitations................................................................................................ 19
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204-3 Design...................................................................................................... 19
204-4 Fabrication……………………………………………………………………………………….…………………21

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 204-5 Examination ............................................................................................ 22
204- 6 Testing .................................................................................................... 22
Article 205 Weld Ring Gaskets (Welded Lip Seals) .................................................. 23
205- 1 Description .............................................................................................. 23
205-2 Limitations ............................................................................................... 23
205-3 Design ..................................................................................................... 23
205-4 Fabrication .............................................................................................. 24
205-5 NDE Examinations .................................................................................. 27
205-6 Testing .................................................................................................... 27

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205- 7 References .............................................................................................. 27

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Article 206 Full Encirclement Steel Reinforcing Sleeves for Piping ................................................................. 28
206- 1 Description .............................................................................................. 28
206-2 Cautions and Limitations……………………………………………………………………… 28

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206-3 Design ..................................................................................................... 29
206-4 Fabrication .............................................................................................. 31
206-6 Testing .................................................................................................... 33

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206- 7 References .............................................................................................. 33
Article 207 Fillet WeldedPatches With Reinforcing Plug Welds ................................ 35
207- 1 Description .............................................................................................. 35
207-2
207-3 O
Limitations ............................................................................................... 35
Design ..................................................................................................... 35
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207-4 Fabrication .............................................................................................. 39
207-5 Examination ............................................................................................ 40
207-6 Testing .................................................................................................... 40
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207- 7 References .............................................................................................. 40

Article 208 Alternatives to Traditional Welding Preheat .................................................................................. 41
208- 1 Description .............................................................................................. 41
208-2 Limitations ............................................................................................... 41
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208-3 Design ..................................................................................................... 41

208-4 Fabrication .............................................................................................. 43
208-5 Examination ............................................................................................ 44
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208-6 Testing .................................................................................................... 44

208- 7 References .............................................................................................. 44
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Article 209 Alternatives to Post weld Heat Treatment .................................................................. 47

209- 1 Description .............................................................................................. 47
209-2 Limitations ............................................................................................... 47
209-3 Design ..................................................................................................... 48
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209-4 Fabrication .............................................................................................. 48

209-5 Examination ............................................................................................ 48
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209-6 Testing .................................................................................................... 48

209- 7 References .............................................................................................. 49
Article 210 In-Service Welding Onto Carbon Steel Pressure Components or Pipelines…………………..…… 50
210- 1 Description .............................................................................................. 50
210-2 Limitations ............................................................................................... 51

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 210-3 Design ..................................................................................................... SI
210-4 Fabrication.............................................................................................. S2
210-5 Examination............................................................................................ S6
210-6 Testing..................................................................................................... 56
210- 7 References .............................................................................................. 58
Mandatory Appendix 210-1 In-Service WeldingProcedure/Welder Performance Qualification Setup………… 60
Article 211 Weld Buildup. Weld Overlay, and Clad Restoration ................................ 62
211- 1 Description .............................................................................................. 62

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211-2 Limitations ............................................................................................... 62

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211-3 Design ..................................................................................................... 62
211-4 Fabrication............................................................................................... 63
211-5 Examination............................................................................................. 65

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211-6 Testing..................................................................................................... 65
211- 7 References .............................................................................................. 67
Article 212 Fillet Welded Patches .............................................................................. 68

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212- 1 Description .............................................................................................. 68
212-2 Limitations ............................................................................................... 68
212-3 Design ..................................................................................................... 68
212-4
212-5 O
Fabrication............................................................................................... 71
Examination............................................................................................. 72
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212-6 Testing..................................................................................................... 72
212- 7 References .............................................................................................. 72
Article 213 Threaded or Welded Plug Repairs .......................................................... 74
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213- 1 Description .............................................................................................. 74

213-2 Limitations ............................................................................................... 74
213-3 Design ..................................................................................................... 74
213-4 Fabrication............................................................................................... 74
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213-5 Examination............................................................................................. 75
213-6 Testing..................................................................................................... 75
213- 7 References .............................................................................................. 75
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Article 214 Field Heat Treating of Vessels ................................................................ 77

214- 1 Description .............................................................................................. 77
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214-2 Limitations ............................................................................................... 77

214-3 Design ..................................................................................................... 77
214-4 Fabrication............................................................................................... 80
214-5 Examination............................................................................................. 81
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214-6 Testing..................................................................................................... 81
214- 7 References .............................................................................................. 81
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Mandatory Appendix 214-1 Developing a HeatTreatment Procedure ................................................. 82

Mandatory Appendix 214-11 Typical Hot BoxDesign ............................................................................ 83
Article 215 Repair WeldingConsiderations for Cr-Mo Steel Pressure Vessels ………85
215- 1 Description .............................................................................................. 85
215-2 Limitations ............................................................................................... 85
215-3 Design ..................................................................................................... 85

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 215-4 Fabrication ............................................................................................... 86
215-5 Examination ............................................................................................. 86
215-6 Pressure Testing ..................................................................................... 87
215- 7 References .............................................................................................. 87
Article 216 Welded Hot Taps in Pressure Equipment or Pipelines ............................ 96
216- 1 Description .............................................................................................. 96
216-2 Limitations ............................................................................................... 97
216-3 Design ..................................................................................................... 98
216-4 Fabrication ............................................................................................. 102

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216-5 Examination ........................................................................................... 103

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216-6 Pressure Testing ................................................................................... 104
216-7 References ............................................................................................ 105
Nonmandatory Appendix 216-A Glossary of Acronyms ................................................................................. 107

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Part 3 Mechanical Repairs ............................................................................... 108
Article 301 Replacement of PressureComponents .................................................. 108
301-1 Description ............................................................................................ 108

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301-2 Limitations ............................................................................................. 108
301-3 Design ................................................................................................... 108
301-4 Fabrication ............................................................................................. 108
301-5
301-6 O
Examination ........................................................................................... 109
Testing................................................................................................... 109
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301- 7 References ............................................................................................ 109
Article 302 Freeze Plugs ......................................................................................... 110
302- 1 Description ............................................................................................ 110
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302-2 Limitations ............................................................................................. 110

302-3 Design ...................................................................................................... Ill
302-4 Fabrication ............................................................................................. 112
302-5 Examination ........................................................................................... 114
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302- 6 Testing................................................................................................... 115

Article 303 Damaged Threads in Tapped Holes ...................................................... 116
303- 1 Description ............................................................................................ 116
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303-2 Limitations ............................................................................................. 116

303-3 Design ................................................................................................... 117
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303-4 Fabrication ............................................................................................. 117

303-5 Examination ........................................................................................... 118
303-6 Testing................................................................................................... 118
303-7 References ............................................................................................ 118
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Mandatory Appendix 303-1 Recommended Detail forStud Threads Modification to Prevent Damage to Threads in
Tapped Holes…………………………………………………………………………………………………………….119
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Mandatory Appendix 303-11 An Illustrative Example Showing an Engineering Analysis Associated

With Enlarging a Tapped Hole ....................................................................................................................... 122
303-II-1 Example 1 ............................................................................................. 122
303- II-2 Example 2 ............................................................................................. 124
Article 304 Flaw Excavation and Weld Repair ........................................................ 126
304- 1 Description ............................................................................................ 126
304-2 Limitations ............................................................................................. 126

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 304-3 Design................................................................................................... 127
304-4 Fabrication ............................................................................................ 128
304-5 Examination .......................................................................................... 129
304-6 Testing .................................................................................................. 129
304-7 References ........................................................................................... 129
Mandatory Appendix 304-1 Metal Removal Process ........................................................................ 130
304-1-1 Flapping ................................................................................................ 130
304-1-2 Grinding ................................................................................................ 130
304-1-3 Honing .................................................................................................. 130

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304-1-4 Lapping ................................................................................................. 130

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304-1-5 Machining ............................................................................................. 130
304-1-6 Thermal Gouging .................................................................................. 131
304- 1-7 Boat Sample Cutting ............................................................................. 131

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Article 305 Flange Repair and Conversion ............................................................. 133
305- 1 Description ............................................................................................ 133
305-2 Limitations............................................................................................. 133

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305-3 Design................................................................................................... 133
305-4 Fabrication ............................................................................................ 134
305-5 Examination .......................................................................................... 135
305-6
305- 7 O
Testing .................................................................................................. 135
References ........................................................................................... 135
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Article 306 Mechanical Clamp Repair ..................................................................... 136
306- 1 Description ............................................................................................ 136
306-2 Limitations............................................................................................. 136
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306-3 Design................................................................................................... 137

306-4 Fabrication ............................................................................................ 139
306-5 Examination .......................................................................................... 139
306-6 Testing .................................................................................................. 139
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306- 7 References ........................................................................................... 139

Article 307 Pipe Straightening or Alignment Bending ............................................. 140
307- 1 Description ............................................................................................ 140
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307-2 Limitations............................................................................................. 140

307-3 Design................................................................................................... 140
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307-4 Fabrication ............................................................................................ 141

307-5 Examination .......................................................................................... 141
307-6 Testing .................................................................................................. 142
307- 7 Reference ............................................................................................. 142
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Article 308 Damaged Anchors in Concrete (Post installed Mechanical Anchors)……………………………….143

308- 1 Description ............................................................................................ 143
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308-2 Limitations............................................................................................. 144

308-3 Design................................................................................................... 144
308-4 Fabrication ............................................................................................ 145
308-5 Examination .......................................................................................... 149
308-6 Testing .................................................................................................. 149
308-7 References ........................................................................................... 149

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 Mandatory Appendix 308-1 Anchors Installation Using Chemical Means (Adhesive)........................ 151
308-1-1 Adhesive Anchors .................................................................................. 151
Article 309 Valves With Pressure Seal-Type Bonnets ............................................. 152
Article 310 Hot Bolting ............................................................................................. 153
Article 311 Hot and Half Bolting RemovalProcedures ............................................. 154
311-1 Description............................................................................................. 154
311-2 Limitations ............................................................................................. 154
311-3 Design ................................................................................................... 155
311-4 Fabrication ............................................................................................. 156

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311-5 Examination ........................................................................................... 157

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311-6 Testing ................................................................................................... 157
311- 7 References ............................................................................................ 157
Article 312 Inspection and Repair of Shelland Tube Heat Exchangers ................... 158

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312- 1 Description............................................................................................. 158
312-2 Limitations ............................................................................................. 158
312-3 Design ................................................................................................... 158

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312-4 Fabrication ............................................................................................. 160
312-5 Examination ........................................................................................... 164
312-6 Testing ................................................................................................... 165
312-7
Mandatory Appendix 312-1 O
References ............................................................................................ 165
Methods for Determining Minimum Number of Tubes to Inspect . 166
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312-1-1 Introduction ............................................................................................ 166
Mandatory Appendix 312-11 Examination of Pressure ContainmentComponents .............................. 169
312-II-1 Examination ........................................................................................... 169
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312-II-2 Inspection .............................................................................................. 169

312- II-3 Suitability ............................................................................................... 169
Article 313 Crimping of Metallic Pipe ....................................................................... 170
313- 1 Description............................................................................................. 170
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313-2 Limitations ............................................................................................. 170

313-3 Design ................................................................................................... 170
313-4 Fabrication ............................................................................................. 171
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313-5 Examination ........................................................................................... 172

313-6 Testing ................................................................................................... 174
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313-7 References ............................................................................................ 174

Part 4 Nonmetallic and Bonded Repairs .......................................................... 175
Article 401 Nonmetallic Composite RepairSystems:High-Risk Applications ………..175
401-1 Description............................................................................................. 175
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401-2 Limitations ............................................................................................. 176

401-3 Design ................................................................................................... 176
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401-4 Fabrication (Installation) ........................................................................ 185

401-5 Examination ........................................................................................... 187
401-6 System Pressure Testing....................................................................... 189
401-7 References ............................................................................................ 189
Mandatory Appendix 401-1 Design Data Sheet ................................................................................ 192
Mandatory Appendix 401-11 Qualification Data for the Repair System ............................................... 195

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 401-II-1 Introduction ............................................................................................ 195
401-II-2 Data for Repair Laminate ....................................................................... 195
401-II-3 Data for Repair/Substrate Interface ....................................................... 195
401-II-4 Additional Requirements for Structural Repairs to Nonleaking
Components (Type A Design Case)............................................................................................................. 196
401-II-5 Additional Requirements for Leaking Components (Type B Design Case) 196
401-II-6 Performance Testing (Optional Qualification Tests) ............................... 196
Mandatory Appendix 401-III Slotting Pipe Spool Survival Test ........................................................... 197
401-III-1 Introduction ............................................................................................ 197
401-III-2 Method ................................................................................................... 197

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401-III-3 Report .................................................................................................... 197

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Mandatory Appendix 401-IV Measurement of y for Leaking Defect Calculation.................................. 199
401-IV-4 Report .................................................................................................... 200
Mandatory Appendix 401-V Measurement of Performance Test Data ............................................... 201

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401-V-l Introduction ............................................................................................ 201
401-V-2 Methods ................................................................................................. 201
401-V-3 Report .................................................................................................... 202

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Mandatory Appendix 401-VI Measurement of Impact Performance .................................................... 203
401-VI-l Introduction ............................................................................................ 203
401-VI-2 Methods ................................................................................................. 203
401-VI-3
Mandatory Appendix 401-VII O
Report .................................................................................................... 203
Installer Qualification .............................................................................. 204
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401-VII-l Introduction ............................................................................................ 204
401-VII-2 Training .................................................................................................. 204
401-VII-3 Training Records.................................................................................... 204
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401-VII-4 Requalification ....................................................................................... 205

Mandatory Appendix 401-VII! Installation .............................................................................................. 206
401-VIII-l Introduction ............................................................................................ 206
401-VIII-2 Surface Preparation ............................................................................... 206
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401-VIII-3 Laminate Lay-Up.................................................................................... 206

401-VIII-4 Cure ....................................................................................................... 206
401-VIII-5 Documentation ....................................................................................... 206
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Nonmandatory Appendix 401-A Glossary of Terms and Acronyms ............................................................... 208

401-A-l Glossary of Terms.................................................................................. 208
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401-A-2 Glossary of Acronyms ............................................................................ 209

Nonmandatory Appendix 401-B Recommended Retesting for a Modified Qualified Repair System …………210
401-B-l General .................................................................................................. 210
401-B-2 Modified Repair System ......................................................................... 210
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401- B-3 Engineering Judgment ........................................................................... 210

Article 402 Nonmetallic Composite Repair Systems: Low-Risk Applications ……….213
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402- 1 Description ............................................................................................. 213

402-2 Limitations .............................................................................................. 214
402-3 Design .................................................................................................... 214
402-4 Fabrication (Installation) ......................................................................... 216
402-5 Examination ........................................................................................... 217

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 402-6 System Pressure Testing……………………..………………...…………………….. 217
402-7 References…………………………………………………………………………….... 217
Mandatory Appendix 402-1 Repair Data Sheet………………………………………………………………..……..221
Mandatory Appendix 402-11 Qualification Data for Repair System………………………………………………... 223
402-II-1 Introduction………………………………………………………………………….…...223
402-II-2 Data for Repair Laminate…………………...……………………………………..….. 223
402-II-3 Data for Composite/Substrate Interface………………………………………….….. 223
402-II-4 Additional Requirements for Leaking Substrates…………………………………… 223
Mandatory Appendix 402-III Validation for Repair of Leaking Component…………………………………………224

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402-III-1 Introduction……………………………………………………………………………….224

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402-III-2 Method…………………………………………………………………………………... 224
402-III-3 Report……………………………………………………………………………………. 224
Mandatory Appendix 402-IV Installer Qualification…………………...……………………………………………… 225

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402-IV-l Introduction……………………………………………………………………………… 225
402-IV-2 Training………………………………………………………………………………….. 225
402-IV-3 Training Records……………………………………………………………………….. 225

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402-IV-4 Qualification Period…………………………………………………………………….. 225
Mandatory Appendix 402-V Installation………………………………………………………………………………. 226
402-V-l Introduction……………………………………………………………………………… 226
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402-V-3 O
Surface Preparation……………………………………………………………………. 226
Laminate Lay-Up……………………………………………………………………….. 226
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402-V-4 Cure……………………………………………………………………………………… 226
402-V-5 Documentation………………………………………………………………………….. 226
Nonmandatory Appendix 402-A Glossary of Terms and Acronyms………………………………………………… 227
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402-A-l Glossary of Terms……………………………………………………………………… 227

402- A-2 Glossary of Acronyms………………………………………………………………….. 227
Article 403 Nonmetallic Internal Lining for Pipe: Sprayed Form for Buried Pipe
………………229
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403- 1 Description………………………………………………………………………………. 229

403-2 Cautions and Limitations………………………………………………………………..229
403-3 Design……………………………………………………………………………...……. 230
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403-4 Fabrication (Installation) ………………………………………………….…………… 232

403-5 Examination………………………………………………………………………………233
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403-6 Testing…………………………………………………………………………………… 234

403-7 References……………………………………………………………………………… 234
Mandatory Appendix 403-1 Design Considerations for Buried Pipe…………………………………………….… 237
403-1-1 Wall Thickness of CIPP…………………………………………………………….….. 237
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403-1-2 Design Equations…………………………………………………………………….… 237

403-1-3 Applied Loads Design……………………………………………………………….…..238
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Mandatory Appendix 403-11 Inspection/Examination and Corrective Action Requirements for CIPP……….…..239
403-II-1 General……………………………………………………………………………………239
403-II-2 Polymer Mixture…………………………………………………………………………239
403-II-3 Polymer Thickness Sampling………………………………………………………….239
403-II-4 Polymer Hardness………………………………………………………………………239
403-II-5 Polymer Coverage………………………………………………………………………239

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 403-II-6 Surface Defect Corrective Actions .......................................................... 239
403-II-7 Corrective Action for Areas of Insufficient Curing.................................... 240
Mandatory Appendix 403-III Glossary of Terms and Acronyms ........................................................... 241
403-III-1 Glossary of Terms................................................................................... 241
403-III-2 Glossary of Acronyms ............................................................................. 241
Part 5 Examination and Testing ........................................................................ 242
Article 501 Pressure and Tightness Testing of Piping and Equipment ..................... 242
501-1 Description .............................................................................................. 242
501-2 Limitations ............................................................................................... 242

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501-3 Design ..................................................................................................... 242

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501-4 Fabrication .............................................................................................. 245
501-5 Examination ............................................................................................ 245
501-6 Testing .................................................................................................... 245

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501-7 References ............................................................................................. 250
Mandatory Appendix 501-1 Pressure/Leak Testing ............................................................................ 251
Mandatory Appendix 501-11 Stored Energy Calculations for Pneumatic Pressure Test ...................... 253

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501-II-1 General ................................................................................................... 253
Mandatory Appendix 501-111 Safe Distance Calculations for Pneumatic Pressure Test ....................... 254
50l-III-l Blast Wave Distance ............................................................................... 254
501-III-2
Mandatory Appendix 501-1V O
Fragment Throw Distance ....................................................................... 254
Risk Evaluation Considerations for Pneumatic Pressure Test .... 256
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501-IV-l Introduction ............................................................................................. 256
501-IV-2 Pneumatic Test Risk Considerations ...................................................... 256
501- IV-3 Piping System Volume Considerations ................................................... 256
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Article 502 Nondestructive Examination in Lieu of Pressure Testing for Repairs

and Alterations ................................................................................................................................................. 258
502-1 Description .............................................................................................. 258
502-2 Limitations ............................................................................................... 259
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502-3 Design ..................................................................................................... 259

502-4 Fabrication (Repair or Alteration) ............................................................ 259
502-5 Examination — Nondestructive Examination (NDE) ............................... 259
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502-6 Testing .................................................................................................... 260

502- 7 References ............................................................................................. 260
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Mandatory Appendix 502-1 Comparison of Selected NDE Methods .................................................. 261

Article 503 Test Devices for Localized Pressure or Tightness Testing of Welded
Repairs ............................................................................................................................................................. 264
503- 1 Description .............................................................................................. 264
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503-2 Limitations ............................................................................................... 264

503-3 Design ..................................................................................................... 264
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503-4 Fabrication .............................................................................................. 266

503-5 Examination ............................................................................................ 267
503-6 Testing .................................................................................................... 269
503-7 References ............................................................................................. 269
Figures
201-3.5-1 Flush Insert in Pipe or Tube ........................................................................ 5

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 201-3.8-1 Flush Insert Plate (With or Without Nozzle/Manway) With Its Butt Weld
Intersecting Existing Butt Weld in Shells or Heads……………………..………5
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 …………………………………………………….6
202- 3-1 Weld Buildup Profile………………………………………………………………11
204- 1-1 Example of a Welded Leak Box Repair of a Tee…………………………….. 20
205- 1-1 Membrane Weld Ring Gaskets………………………………………………….23
205-1-2 Weld Ring Gaskets……………………………………………………………….24
205-1-3 Hollow-Lip Weld Ring Gaskets…………………………………………………..24

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205-4.3-1 Centering Pin Arrangement……………………………………………………...26

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205-4.3-2 Clamped Lip Seal…………………………………………………………………26
205- 4.3-3 Assembled Up Seal……………………………………………………………….27
206- 1.1.1-1 Type A Sleeve……………………………………………………………………..29

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206-1.1.2-1 Type B Sleeve……………………………………………………………………..30
206-2.7-1 Welded Split Sleeve for Use Over a Girth Weld……………………………….31
206-3.5-1 Type B Sleeve Fillet Weld Size for Sleeve Thickness Less Than or Equal to

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1.4 Times the Carrier Pipe Thickness ........................................................................................................... 32
206- 3.5-2 Type B Sleeve Fillet Weld Size for Sleeve Thickness Greater Than 1.4
Times

207- 1-1 O
the Carrier Pipe Thickness ................................................................................................................................. 32
Typical Shell Repair Near Discontinuity .................................................... 36
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208- 3.1-1 Typical Residual Stresses in a Weld ......................................................... 42
208-3.1-2 Effect of Weld Area on Transverse Shrinkage .......................................... 42
208-4.2-1 Typical Back Stepping Weld Sequence .................................................... 44
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208-4.2-2 Difference Between Oscillated Stringer Beads (Left) and Wide Weave
Beads (Right) ..................................................................................................................................................... 44
208-4.4-1 Effect of Weld Bead Cross Section on Cracking ....................................... 45
210-4.2.1.2-1 Heat-Affected Zone Hardness Indent Locations ....................................... 54
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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 .......................................................................................................................... 55
210-4.2.1.4-2 Examples of In-Service Welding Procedure Qualification Face Bred Test
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Samples …………………………………………………….……………………………………………………………….55
210-4.2.2-1 Test Sample Locations for In-Service Fillet Welding Procedure
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Qualification Assuming Equal Spacing Around the Circumference to Obtain All the Required Test Specimens 56
210-4.2.2.2-2 Test Sample Locations for In-Service Attachment Welding Procedure
Qualification Assuming Equal Spacing Around the Circumference to Obtain All the Required Test Specimens 57
210-4.2.2-3 Test Sample Locations for In-Service Weld Metal Buildup Welding
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Procedure Qualification ...................................................................................................................................... 58

210-1-1 Procedure and Welder Qualification Test Assembly for an In-Service Fillet Weld…………………… 60
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210- 1-2 Procedure and Welder Qualification Test Assembly for an In-Service Attachment Weld……………. 61
211- 4.4.1-1 Weld Seam With Back Cladding ............................................................... 64
212- 1-1 Typical Shell Repair Near Discontinuity .................................................... 69
213- 3.1-1 Typical Plug Arrangement......................................................................... 76
214- II-1 Typical Hot Box Design............................................................................. 84
215- 3.1-1 Standard Steps in Repair Welding ............................................................ 90

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 215-3.3-1 Examples of Damage Common to Cr-Mo Pressure Vessels ..................... 92
215- 3.4-1 Flowchart for the Selection of Repair WeldingMethods............................. 93
216- 1.2-1 Typical Hot Tapping Setup ........................................................................ 97
302- 3.6.3-1 Nitrogen Freeze Plug Assembly .............................................................. 113
303- 3.3.3-1 Example of Tapered Stud ....................................................................... 118
303-1-1 Inch Thread Series (U.S. Customary Units) ............................................ 119
303-1-2 Inch Thread Series (SI Units) .................................................................. 120
303- 1-3 Metric Thread Series (SI Units) ............................................................... 121
304- 3.1-1 Excavation and Weld Repair of Surface Flaw ......................................... 127
304-3.1-2 Excavation and Weld Repair of Embedded Flaw .................................... 127

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304-3.1-3 Grinding of Weld Flaw ............................................................................. 128

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304- 1-7-1 Boat Sample............................................................................................ 132
305- 4.5.2-1 Flange Dimensions ................................................................................. 135
306- 1-1 Example of a Mechanical Clamp ............................................................. 136

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306-1-2 Square Mechanical Clamp Over Drain Branch, With Sealant Injection
Nozzle…………………………………………………………………………..137
308-1.3-1 Anchors ................................................................................................... 143

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308-1.5-1 Anchor and Concrete Failure .................................................................. 144
308-1.7-1 Column Base Anchors in Concrete ......................................................... 145
308-4.1-1 Weld Repair of Existing Rod ................................................................... 146
308-4.3.1-1
308-4.3.2-1 O
Wedge Anchor ........................................................................................ 147
Sleeve Anchor ......................................................................................... 147
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308-4.5.1.1-1 Relocation of One or Two Anchors Within an Arc (r = 1/2d)……………..148
308-4.5.1.1-2 Relocation of One or Two Anchors Within an Arc (r = d)………………..148
308-4.6.1-1 Relocation of One or Two Anchors Within a Design Plate Assembly…. 149
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308-4.6.2-1 Relocation of More Than Two Anchors Within a Design PlateAssembly150

308-4.6.3-1 Using an Enlarged Plate ......................................................................... 150
312-4.2-1 Typical Friction Fit Tapered Tube Plug ................................................... 161
312-4.2-2 Typical Mechanical Fit Tube Plugs ......................................................... 162
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312-4.2-3 Typical Installation of Mechanical Fit Tube Plugs.................................... 162

312-4.2-4 Sample Chart: Number of Tube Failures by Month ................................. 163
313-4.1-1 Crimp Block on Pipe................................................................................ 172
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313-4.1-2 Crimp With Injection Arrangement .......................................................... 173

313-4.1-3 Crimp Clamp in Position (Right) and Sealant Injection Box (Left) .... 173
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401-5.1-1 Schematic of a Repair System and Location ofDefects .......................... 188

401-II-2-1 Test Specimen Geometry ....................................................................... 195
401-III-2-1 Defect Dimensions .................................................................................. 198
403-1.1-1 Structural Liner in Raw Water System .................................................... 230
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501-3.3-1 Test Type Selection ................................................................................ 244

50 l-IV-3-1 A Schematic Diagram of a Pipeline Burst, Showing the Flow of Gas Within
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the Pipes………………………………………………………………………..257
503-1.1.2-1 Hydrotest Device Types .......................................................................... 265
503-4-1 Hydrotest Device Seal Location .............................................................. 267
503-4.1-1 Type I Hydrotest Device With Lanyard .................................................... 267
503-4.1-2 Type I Hydrotest Device Without Lanyard ............................................... 268
503-4.1-3 Type I Typical Installations ...................................................................... 268

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 503-4.2-1 Location of Split Ring Flange................................................................... 269
503-4.4-1 Type IV Device ........................................................................................ 269
Tables
208- 3.3-1 Comparison of Specification and Actual Weld Metal Properties ................ 43
209- 4.1-1 Summary of Post weld Heat Treatment Requirements and Potential
Alternatives ........................................................................................................................................................ 48
210- 4.2.1-1 Type and Number of Test Specimens Required for an In-Service Welding
Procedure Qualification ...................................................................................................................................... 53
215-1.1-1 Guide for the Selection of Repair Technique ............................................. 89

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215-1.2-1 Cr-Mo Steels Applicable to This Article ..................................................... 89

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215-3.2-1 Typical In-Service Degradation ................................................................. 91
215-3.2-2 Typical Considerations for Weld Repair of In-Service Degradation .... 91
215-3.5-1 Repair Methods Applicable to Cr-Mo Vessels ........................................... 93

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215-4.1-1 Repair Approach Sequence ...................................................................... 94
215-4.4-1 Typical Preheat and Interpass Temperatures............................................ 94
215-4.5-1 De-Embrittlement Heat Treatment ............................................................. 95

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308-4.3-1 Minimum Edge Distance for Punched. Reamed, or Drilled Holes ........ 147
308-4.3-2 Expansion Anchor — Illustrative Example of Typical Minimum Limits for
Reference ......................................................................................................................................................... 147
312-1-1.3-1
401-3.2-1 O
Inspection Effectiveness Table ................................................................ 167
Repair System Required Material and Performance Properties .............. 178
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401-3.4.2-1 Service Temperature Limits for Repair Systems ..................................... 181
401-3.4.4-1 Allowable (Long-Term) Strains for Repair Laminates (No Allowance for
Temperature Effects) ........................................................................................................................................ 182
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401-3.4.5-1 Service Factors for Repair Laminates ..................................................... 183

401-4.6-1 Hold Points During Installation ................................................................ 187
401-5.2-1 Defect Type and Allowable Limits for the Composite Wrap ..................... 188
401-IV-3-1 Student's tv Value for Double-Sided 0.025 Level of Significance ............. 200
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401- B-2-1 Recommended Testing for Requalification of a Modified Qualified Repair

System ............................................................................................................................................................. 211
402- 3.2-1 Repair System Required Material and Performance Properties .............. 215
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402-4.4-1 Hold Points During Installation ................................................................ 217

402-5.2-1 Defect Type and Allowable Limits for the Composite Repair ................... 218
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501-III-1-1 Alternative Values for ............................................................................. 254

501- III-2-1 Minimum Distances for Fragment Throw Considerations ........................ 255
502- 1-1 Comparison of Selected NDE Methods ................................................... 262
503- 3-1 Device Type Selection Guidance ............................................................ 265
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Forms
Component Repair Data Sheet ......................................................................................................................... 193
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Repair Data Sheet............................................................................................................................................. 222

Test Record ...................................................................................................................................................... 252

xiv
 ASME PCC-2-2018

PART 2
WELDED REPAIRS
Article 201
Butt-Welded Insert Plates in Pressure Components

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201- 1 DESCRIPTION
201- 2 LIMITATIONS
201- 1.1 General Considerations
The repair of pressure components by butt-welded insert 201- 2.1 Part 1 of This Standard

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plates involves the replacement of pressure boundary Part 1 of this Standard contains additional requirements and
material in a pressure component with an insert plate limitations. This Article shall be used in conjunction with Part 1,
attached by full penetration butt welds. This repair method
201- 2.2 Additional Considerations and
is applicable to cylindrical, spherical, and conical shells and

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to flat pressure components. It may be used for single and Limitations
double curvature shells. It may also be used on other When applying this repair method, consideration shall be given
pressure components [such as formed heads) if the to compatibility of materials, operating conditions for the intended
curvature of the replaced section matches the curvature of life of the component, fitting and welding to minimize the residual
the original pressure part It is not limited by the size of the
pressure component, except where practical considerations
preclude the use of an insert, such as on small diameter pipe O
stresses and distortions, and any limitations on nondestructive
examination and pressure testing.
201- 2.3 Loadings
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or tube. It may be used on small diameter pressure
components if special care is taken to ensure a close fit of This method may be used for equipment subject to either
the insert plate and the existing pressure component and internal or external pressure. If the pressure component is subject
that the repaired pressure component meets the tolerance to external pressure, additional consideration shall also be given to
requirements of the applicable construction code. any loss of buckling strength as a result of permanent distortions
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or misalignment in the repaired component If the pressure

201- 1.2 Replacement of Local Areas in component is subject to cyclic loading, additional consideration
Pressure Vessel Shells or Pipe Walls shall be given to the effect of perm anent distortions on the fatigue life of

This repai r method is intended to be used to replace the repaired component

portions of pressure-retaining vessel shells or pipe walls
201- 2.4 Corrosion-Resistant Weld Overlay or
that have been damaged by cracks, local wall thinning from
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erosion, corrosion, and other damage mechanisms. The

Cladding
insert plate may contain one or more nozzles/ manways. This repair method may also be used in vessels that are either
clad with corrosion-resistant lining or weld overlay. The insert
201- 1.3 Replacement of Entire Component plate cladding or weld overlay shall be compatible with the existing
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Replacement of an entire component, shell plate, or a materials and suitable for the intended service. Consideration shall
complete shell course of a cylindrical shell, or a complete also be given to the use of weld details and welding procedures
circular segment of a sphere, or a complete head, or a section suitable for the intended service.
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of a pipe is not considered in this repair method.

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 ASME PCC-2-2018

201- 2.5 Dissimilar Metals 201- 3.6 Insert Plate Size

Use of dissimilar materials (base metal and welds) is not The insert plate shall be of sufficient size to replace the
prohibited, but the materials shall meet the required minimum entire area of the existing pressure component that has been
mechanical properties for the pressure component and shall assessed as not being fit for continued operation and to
be carefully evaluated for compatibility between the dissimilar ensure that all welds are in sound material.
materials and the service environment, both internal and 201- 3.6.1 Minimum Size of Insert Plates. The
external. If thermal fatigue is a possibility, consideration shall minimum diameter, or length and width dimensions of

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be given to the potential for accelerated fatigue cracking in the nonpostweld heat-treated, butt-welded carbon and low alloy
dissimilar metals combination. steel insert plates shall be the lesser of 12t or 380 mm (15

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in.) (where t is the thickness of the parent material). See para.
201- 3 DESIGN 201-3.8.
201- 3.1 Construction Code 201- 3.7 Structural Stability at Cutouts
The insert plate thickness, material, and welds shall meet Consideration should be given to structural stability and

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the design requirements in the applicable construction code possible distortion of the unsupported plate edges of large
for the existing pressure component into which it is being openings (cutouts] in the vessel shell. An assessment should
installed and shall be consistent with the joint efficiency or be made for the need of temporary supports around the
unsupported edges of such openings during removal of the

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joint quality factors used in the original design, except as
permitted in para. 201-3.3. The allowable stresses shall be the shell section to be replaced with an insert plate. The
same as in the applicable construction code for the existing assessment shall consider all loading conditions that may
component occur on the vessel and the component during the repair,
including structural stability of vessels during PWHT.
201- 3.2 Materials
Insert plates and welds should be of the same material as O
201- 3.8 Insert Plates With Nozzles
The nozzle/manway reinforcement in insert plates with
(18)
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the existing pressure component, or of another material that nozzles shall meet the design requirements and weld details
has at least equal notch toughness and allowable stress, of the applicable construction code for the pressure
conforms to the requirements of the applicable construction component. The minimum diameter of insert plate with a
code, and is suitable for the intended service. Where ASME nozzle shall be the larger of the following:
materials are used, the replacement material should have the (a) for all nozzle/manway assemblies, the diameter of the
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same ASME P-Number designation as the pressure component nozzle/manway penetration plus the width needed for
material into which the insert is being installed. nozzle reinforcement and any edge bevels
(b) for carbon and low alloy steel nozzle/manway
201- 3.3 Insert Plate Thickness assemblies for which the nozzle-to-butt patch (shell] weld is
The insert plate thickness should be not less than the not post weld heat treated before or after the assembly is
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nominal thickness of the material it welds into. If a thinner welded into the shell, the diameter of the insert plate needed
insert plate than the nominal thickness of the material it welds to maintain a minimum distance of 150 mm (6 in.) between
into must be used, it shall be evaluated for the intended service the nozzle attachment weld and the nearest edge of the insert
(such as fatigue due to cyclic loading] using the rules in the plate butt weld. However, the diameter of the insert plate for
applicable construction code for the pressure component, or nozzles having an outside diameter 300 mm (12 in.) or
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the applicable post-construction code. See para. 201-4.1.5. smaller need not be larger than 2 times the outside diameter
of the nozzle. (See also Figures 201-3.8-1 and 201-3.8-2.)
201- 3.4 Rectangular and Square Insert Plates
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Rectangular and square insert plates shall have corners

rounded to a radius, except when the entire shell plate is
replaced. Rectangular and square insert plates 13 mm (1/2in.)
thick and up to and including 25 mm (1 in.) thick should have
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a 75 mm (3 in.) or a larger corner radius. Insert plates less than

13 mm (1/2 in.) thick may have smaller corner radii. Insert
plates over 25 mm (1 in.)thick should have a 150 mm (6 in.) or
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a larger corner radius.

201- 3.5 Flush Inserts

Flush inserts in pipe or tube may be round or oblong
cutouts, as shown in Figure 201-3.5-1, or rectangular
cutouts with rounded corners.

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 ASME PCC-2-2018

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NOTES:
(1) Existing buttweld in vessel shell or head. (Figure 201-
3.8-1 shows butt weld in a cylindrical shell.)
(2] Thirty deg minimum angle.
(3] Full RT or UT, or MT or PT both sides of existing butt
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weld, 100 mm (4 in.) min. each side of intersection with

insert plate.
NOTES: (4] Insert plate butt weld. Full RT or UT, or MT or PT both
1) Side view of cutout in pipe or tube with edge bevels. sides of weld.
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(Figure 201- 3.5-1 shows single-grooved joint detail (5) See para. 201-3.8.
with 25 deg to 35 degage bevel in pipe or tube.
Other joint details and edge bevels may be used, as
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appropriate for a particular weld joint]

(2) Plan view of insert with edge bevels. (Figure 201-
3.5-1 shows an insert with one-sided joint detail.)
(3) Side view of the insert with edge bevels. (Other joint
details and edge bevels may be used, as appropriate
for a particular weld joint)
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(4) Side view of welded insert in pipe or tube.

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5
 ASME PCC-2-2018

it has been installed and welded into the vessel shell, pipe,
or tube. For pipe or tube inserts, the insert may also be cut
from another piece of pipe or tube of the same diameter
and thickness as the pipe or tube to be repaired. Thicker
pipe or tube inserts may be used, provided they meet the
requirements of para. 201-4.1.5.
201-4.1.3 Forming Strains in Carbon and Low Alloy

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Steels. Carbon steel and low alloy steel insert plates should
be heat treated (stress relieved, normalized, or quenched

NL
and tempered, if appropriate) subsequently when the
resulting extreme fiber elongation during cold forming is
more than 5%, as determined by the following formulas:
(a) For single curvature shells (cylinders)

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NOTES:
(1) Existing buttweld in vessel shell or head. (Figure 201-3.8-2 O
where
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shows butt weld in a cylindrical shell.) Rf = final centerline radius, mm (in.)
(2) Length of cut in shell buttweld, 150 mm (6 in.) minimum on R o = original centerline radius, mm (in.). (Radius equals
each side of intersecting insert plate butt weld. infinity for flat plate.) t = plate thickness, mm (in.)
(3) Insert plate butt weld.
(4) Cut existing shell butt weld to 150 mm (6 in.) minimum on As an alternative, the rules of the original construction code
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each side of intersecting insert plate butt weld and bevel may be used.
edges (or arc gouge edges) to the desired edge bevels.
Reweld after completion of insert plate butt weld. Full RT 201-4.1.4 Forming Strains in Other Materials. Cold forming
or UT, or MT or PT both sides of new weld. strains (e.g., from bending) in materials other than carbon
(5) See para. 201-3.8. and low alloy steel shall not exceed the limitations in the
applicable construction code without a subsequent heat
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treatment
201- 4.1.5 Alignment at Edges of Insert Plate. The
201- 4 FABRICATION alignment at edges of the insert plate butt weld shall be
such that the maximum offset is within the limitations of
201- 4.1 Cutting and Forming the applicable construction code for the pressure
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Edge bevels in the insert plate and in

201-4.1.1 Edge Bevels. component. If the insert plate thickness exceeds these
the pressure component may be prepared by thermal limitations, the edge(s) of the insert plate shall have a
ST

cutting, arc gouging, machining, or grinding. The method tapered transition having a length not less than 3 times the
should be appropriate for the material and welding offset between the adjacent surfaces of abutting sections.
process(es) used.
All edges prepared for welding shall be examined to the 201- 4.2 Welding
requirements of the applicable construction code or 201-4.2.1 Welded Joints. The weld between the insert plate
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postconstruction code for the pressure component being and the existing pressure component shall be a full
repaired. All unacceptable indications shall be repaired to penetration butt weld. Where possible, double-welded butt
the requirements of the applicable construction code or joints should be used.
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post-construction code.
201-4.1.2 Forming. Forming the insert plate to the
desired shape may be accomplished by any process that
does not impair the properties of the plate material. It
may be rolled or pressed to the proper curvature such
that it conforms to the curvature of the vessel shell after

6
 ASME PCC-2-2018

201- 4.2.2 Strength of Welded Joints. The welded joints 2010-4.2.9 Weld Contour. The accessible surfaces of
[weld metal and heat-affected zones] shall meet the insert plate butt welds shall preferably be ground2 to a
minimum strength1 and toughness requirements and other smooth contour, or flush if warranted by the service condi-
requirements in the current edition of the applicable tions. The weld toe regions shall blend smoothly with the
construction code for the pressure component base material. The reduction of thickness due to grinding
shall not exceed 0.8 mm [1/32 in.) or 10% of the nominal

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201- 4.2.3 Qualification of Welding Procedures and
Welders. Welding procedures, welders, and welding thickness of the adjoining surface, whichever is less. In no
operators shall be qualified in accordance with the case shall the final thickness be less than the required

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requirements of the applicable construction code or post- thickness.
construction code. Welding procedure qualifications shall 201- 4.3 Weld Spacing Between Nonintersecting Adjacent
include impact tests as required by the applicable Butt Welds in Carbon Steel and Low Alloy Steel
construction code for the pressure component. Vessel
Pressure Components

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[production] impact tests are not required.
201- 4.3.1 Minimum Spacing Between Nonpostweld
201-4.2.4 Welding Materials. Welding materials and
Heat-Treated Butt Welds. Nonpostweld heat-treated butt
processes shall be as currently permitted by the applicable
welds around the periphery of insert plates shall be spaced

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construction code or post-construction code for the
no closer to existing nonpostweld heat- treated butt welds
pressure component. Welding of carbon and low alloy
or reinforcing plate attachment welds than
steels with low hydrogen electrodes and processes is
(a) for t w < 13 mm (1/2 in.), 150 mm (6 in.)
recommended.
(b) for t w > 13 mm (1/2 in.), the greater of 250 mm (10 in.)
201-4.2.5 Welds in Damaged Areas. All welds between
the insert plate and the existing shell should be in sound
material. In some cases, the welds may be in a damaged O and 8t w where
t w = thickness of the thicker of the two adjacent butt
welds, mm (in.)
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area, provided any damage is considered in the design of
the repair, and the damage has been evaluated and is 201- 4.3.2 Alternative Spacing Between Nonpostweld
acceptable by the rules of the applicable post-construction Heat-Treated Butt Welds. The spacing between adjacent
code. nonpostweld heat-treated carbon and low alloy steel butt
welds may be reduced to the lesser of 8tw or 200 mm (8 in.)
201- 4.2.6 Cleaning of Areas to Be Welded. Oil, grease,
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for t w < 40 mm (11/2 in ), provided both butt welds are

paint, scale, and other foreign material shall be removed
ground smooth, 100% RT or UT examined and 100% MT or
from the area adjacent to the weld and a sufficient distance
PT examined after completion of welding in areas where
away from the weld to avoid contamination.
the spacing between the adjacent butt welds is less than
201- 4.2.7 Fit-Up of Insert Plates. Fit-up of insert plates that specified in para. 201-4.3.1. As an alternative, the root
is important to the integrity of the repair. The weld details pass and the weld, after half of the groove is filled, may be
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and welding procedures shall be such as to facilitate full either 100% MT or PT examined in place of the 100% RT
penetration and to minimize distortion and flat spots due or UT examination requirement above. The butt welds with
to weld shrinkage and the risk of weld cracking due to the thicknesses less than 13 mm ( 1/2 in.) need only be MT or
restraint provided by the surrounding material. PT examined. See para.
201 - 5.1.
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201-4.2.8 One-Sided Welds. For flush inserts in pipe or

tube or other pressure components that do not allow two- 201- 4.3.3 Spacing Betwen Stress-Relieved Butt Welds.
sided welding, gas tungsten arc welding, or another The spacing between the adjacent butt welds shall be not
ST

welding process that provides an acceptable weld on the less than 2t w if the first butt weld has been stress-relieved
opposite side should be used for the initial pass joining the before making the second butt weld.
insert to the pipe wall. Subsequent passes may be
completed by gas tungsten arc or another welding process.
201- 4.4 Intersecting Butt Welds in Carbon and
Short Circuit Mode of Gas Metal Arc is not recommended Low Alloy Steel Pressure Components
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for these types of welds. 201-4.4.1 General Considerations. Intersecting insert

plate and existing butt welds should be avoided where
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1 Matching strength filler metal as noted in the AWS 5.X possible. Where it is impractical for the insert plates to
filler metal specifications should be used for welding avoid an existing nonstress-relieved butt weld, the
pressure components. Use of as-deposited weld metal with
substantially greater strength is not 2 Grinding welds to a smooth contour reduces stress
recommended.
concentrations at weld discontinuities.

7
 ASME PCC-2-2018

insert plate butt weld should be placed such that it Examination by the MT or PT methods is recommended
intersects the existing butt weld at an angle not less than for the root pass of single-groove welds and for the back-
30 deg, as shown in Figure 201-3.8-1. Alternatively, the gouge of double-groove welds. No crack-like indications,
insert plate may be sized such that it intersects the existing incomplete fusion, or incomplete penetration are
butt weld at a 90 deg angle, as shown in Figure 201- 3.8-2. permissible.
201-4.4.2 Examination. Unless 100% RT or UT 201- 5.3 Piping
examination is required by the applicable construction

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code, the insert plate butt weld and 100 mm (4 in.) of the For piping, all nondestructive examination
existing butt weld, on both sides of the intersection, shall requirements shall be in accordance with the current

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be 100% MT or PT examined after completion of both requirements in the applicable construction code or
welds, as shown in Figure 201-3.8-1. In case of the postconstruction code.
"doghouse" type insert plate butt weld shown in Figure
201-3.8-2, this examination shall be performed on the full
201- 5.4 Additional Examination
Requirements for Carbon and Low

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length of the new weld along the existing shell butt joint.
See para. 201-5.1. Alloy Steels
201- 4.5 Postweld Heat Treatment 201- 5.4.1 Rectangular and Square Insert Plates. For
rectangular or square insert plates, the welds around the

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201- 4.5.1 General Considerations. The butt welds rounded corners, as a minimum, shall be either spot RT or
between the insert plate and the existing pressure UT examined. As an alternative, the root pass, the weld
component and the weld between the nozzle/manway and after half of the groove is filled, and the completed weld
the insert plate shall be postweld heat treated (PWHT] shall be either MT or PT examined.
when required by the original construction code or the
applicable post-construction code, or for process reasons,
except as permitted by the applicable post-construction
code. Proper precautions should be taken during the PWHT
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201-5.4.2 Closely Spaced and Intersecting Welds. See
paras. 201-4.3 and 201-4.4 for additional examination
requirements for closely spaced welds and intersecting
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to avoid distortion of the welded assembly. welds.

201-4.5.2 Repairs. Repairs to pressure equipment that 201- 6 PRESSURE TESTING

require PWHT based on service conditions shall be
201- 6.1 General Considerations
postweld heat treated, unless other means (e.g.,
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engineering evaluation] are provided to ensure that the as- If the vessel or pipe can be isolated for pressure testing,
welded joints will be suitable for the service conditions, or and if it is practical to do so, all insert plate welds should be
as permitted by the applicable post-construction code. pressure tested as required in the applicable
postconstruction code. Alternatively, nondestructive
201-4.5.3 PWHT. For the repaired pressure parts that examination may be performed in place of pressure testing
require PWHT (either Code-mandated or dependent upon
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if permitted by the applicable post-construction code at the

service conditions], the PWHT shall be performed in location of the pressure equipment, when contamination of
accordance with the applicable construction code, unless the pressure-retaining item by liquids is possible or when
the owner requires a more stringent PWHT (e.g., higher pressure testing is not practical.
PWHT temperature or longer hold time).
201-6.2 Notch Toughness Considerations
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201- 5 EXAMINATION OF WELDS

(a) Consideration should be given to the effect of
201- 5.1 Insert Plate Welds
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service deterioration and embrittlement from prior service

All insert plate welds to the existing pressure conditions on notch toughness characteristics of the
component in pressure vessels shall be examined by radio- pressure component before pressure testing. The
graphic (RT) or ultrasonic (UT)examination methods to the personnel shall maintain a safe distance from the pressure
extent required by the applicable construction code or component when the pressure is increased for the first
post-construction code for the pressure component. Where time.
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UT is used, examination of the root pass by either magnetic Additional safety precautions shall be taken in case of a pneumatic
particle (MT) or liquid-penetrant (PT) methods is test to reduce the risk of brittle fracture.
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recommended. The procedures, personnel qualifications,

and acceptance criteria shall be in accordance with the
applicable construction code or postconstruction code.

201- 5.2 Finished Welded Surfaces

Unless 100% RT or UT examination is required, all finished
welded surfaces shall be examined by magnetic particle (MT) or
liquid-penetrant (PT] methods.

8
 ASME PCC-2-2018

(a) Consideration should also be given to any hazards pressure by pressurizing the component to a desired
that might be associated with the test medium (toxicity, pressure and reducing the pressure to the leak test
flammability, explosiveness, etc.). pressure before performing the leak test.

201-6.3 Leak Test 201-6.4 Vessels and Piping With Insulation or

A separate leak test (visual, bubble-forming solutions, Coating
sniffer, etc.) may be desirable to check for leaks before

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All testing and inspections should be performed prior
pressurizing the component to the maximum test pressure.
to application of insulation or coatings.
Such a leak test should be performed at a safe pressure that

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is substantially less than the maximum test

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RP
PU
U DY
ST
R
FO

9
 ASME PCC-2-2018

Article 202
External Weld Buildup to Repair Internal Thinning

202-1 DESCRIPTION 202-1.1 Introduction

This Article addresses the repair of pressure repair include hydrogen, hydrogen cyanide, oxygen,
components (piping or pressure vessels) degraded by wall alkaline/caustic materials, butadiene, acetylenic
thinning due to flow-accelerated corrosion (FAC), erosion- compounds, H2S, chlorine, and acids. In some cases,
corrosion (EC) and other internal thinning mechanisms by cleaning procedures may be necessary to prepare a
buildup of weld metal on the exterior of the degraded pipe pressure component system for repair.
or pressure vessel section. This Article does not address the 202-2.4 Operation in Creep Temperature Range
repair of cracked components. Buildup repairs of components that are operated at or
near the creep temperature range should only be qualified
202-1.2 Restoration of Wall Thickness
through an engineered design approach as described in
When appropriate, applying a weld buildup repair to section 3 of this Article.
the exterior of a thinning pressure component (pipe/pres-
sure vessel) can provide the necessary structural 202-2.5 Blocked-in Liquid-Filled Components
reinforcement and can eliminate the need for either total Blocked-in liquid-filled components should not be
replacement of the component or an internal weld repair. repaired due to the potential for pressure increase from
Specifically, a weld buildup procedure can be used to thermal expansion.
structurally restore steel (carbon, low alloy, or austenitic 202-3 DESIGN
stainless steel materials suitable for welded construction)
Figure 202-3-1 depicts the weld buildup dimensions
components to the appropriate wall thickness without
referred to in this section.
resorting to replacement efforts. In some cases, it is possible
to perform a repair while the component is in operation. 202-3.1 Buildup Design
The use of a weld buildup as a permanent repair shall The weld buildup shall meet the requirements of paras.
include consideration of the thinning mechanism. 202-3.1.1 through 202-3.2.2.2.
202-3.1.1 Weld Metal
202-2 LIMITATIONS
202-3.1.1.1 Chemistry. The nominal chemistry of the
202-2.1 Additional Requirements deposited weld metal shall match the base material.
Part 1 of this Standard contains additional 202-3.1.1.2 Tensile Strength. The tensile strength of the
requirements and limitations. This Article shall be used in deposited weld metal shall be at least equal to or exceed the
conjunction with Part 1. tensile strength of the base metal to which the weld buildup
is applied.
202-2.2 Cracking
A weld buildup shall not be used for structural 202-3.1.1.3 Alternative Filler Metals. Alternative filler
reinforcement when there is indication of any form of metals (to those specified above) may be used with
cracking. appropriate design calculations and fitness for service
evaluations.
202-2.3 Evaluation of Medium
In all cases, the user shall evaluate the flammability,
volatility, and potential reactions of the medium within the
pressure component prior to application of any welding
process. In no case should welding be performed without a
thorough understanding of the medium contained within
the pressure component This should also include an
evaluation of the medium for potential reactions with the
base material due to the heat from welding. Examples of
process media that should be properly flushed from the
system prior to

10
 ASME PCC-2-2018

202-3.1.2.8 Thickness. The thickness of the

completed buildup, dimension w in Figure 202-3-1, shall not
exceed the nominal thickness of the pressure component
202- 3.1.2.9 Other Configurations.
Configurations not meeting the requirements of paras. 202-
3.1.1 and 202-3.1.2 shall be evaluated based on engineering
analysis (para. 202-3.1.3.2) or testing (para. 202-3.1.3.3).

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201- 3.1.3 Buildup Qualification Requirements. The
design of the weld buildup shall meet one of the following:

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(a) guidelines for prequalified design in para. 202- 3.1.3.1
(b) guidelines for engineered design in para. 202-3.1.3.2
(c) guidelines for proof (burst) test in para. 202-3.1.3.3

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202-3.1.3.1 Prequalified Design. Application of weld
buildups on straight piping sections and associated welds to
correct limited degradation may be considered a prequalified
design and shall be exempt from an engineered design

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qualification or a proof test qualification if all of the
following conditions are met:
(a) All of the requirements of paras. 202-3.1.1 and 202-
3.1.2 are met
(b)The maximum design temperature does not exceed
202- .1.2 Buildup Geometiy General equirements
202- 3.1.2.1 Postrepair Examination. The O
340°C (650°F).
(c) The specified nominal thickness of the existing
RP
design of the buildup shall not hinder postrepair base metal is at least Schedule 40 or Standard Wall,
examinations and evaluations or any preservice whichever is less.
examinations. (d)The maximum angle of the taper does not exceed 30
202- 3.1.2.2 Extension Beyond Base Metal. deg (a in Figure 202-3-1).
The weld shall extend, at full thickness, a minimum distance, (e) The finished buildup is circular, oval, full
PU

B, in each direction beyond the affected base metal [unless circumferential, or rectangular in shape.
otherwise justified by a fitness for service assessment). (f) For each repair, the maximum dimension (L, length
along axis) compensated by a circular, oval, or rectangular
buildup does not exceed the lesser of one-half the nominal
outside diameter of the pressure component or 200 mm [8
where in.).
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R = outer radius of the component, or tnom = 1/2 D (g) Rectangular buildups are aligned parallel with or
nominal wall thickness of the component perpendicular to the axis of th e pres sure component, and corners are
UD

rounded with radii not less than the buildup thickness.

202-3.1.2.3 Edge Taper. The edges of the weld (h) Oval buildups shall have end radii not less than
buildups shall be tapered to the existing pressure and the axis of the buildup shall be aligned parallel with or
component surface at a maximum angle, a , of 45 deg. perpendicular to the axis of the component
202-3.1.2.4 Life of Repair. The thickness shall be (i) The minimum thickness of the buildup shall be
ST

sufficient to maintain the predicted life of the repair. sufficient to restore the nominal wall thickness of the
pressure component. This can be accomplished by
202-3.1.2.5 Corner Radius. All corners of the buildup
shall have a radius, r, not less than the buildup thickness. subtracting the remaining thickness from the nominal
thickness of the component to obtain the required buildup
202- 3.1.2.6 Corrosion Allowance. Any thickness.
corrosion allowance that is determined to be necessary shall (j) The thickness of the buildup shall be relatively
R

be added to these dimensions. The predicted maximum uniform except for the tapered edges.
degradation of the built-up pressure component, and the
buildup, over the design life of the restoration shall be
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analyzed.
202-3.1.2.7 Spacing. In addition, two or more buildups
shall not be spaced any closer than 3⁄4 √𝑅𝑡𝑛𝑜𝑚 between
the toe of each buildup.

11
 ASME PCC-2-2018

(k) If flexibility analysis was required by the original 202- 3.2.1.2 Simulation of Thin Area. To
construction code, the effect of the weld buildup shall be simulate the area of wall-thinning for pressure testing, a
reconciled with the original analysis or qualified in rounded- corner segment of the base material of the mock-
accordance with para. 202-3.1.3.2. up shall be removed to represent the maximum size ratio
202-3.1.3.2 Engineered Design. The weld buildup (axial dimension of L and circumferential dimension of C)
may be qualified by an engineered des ign. The allowable and location of thinning or pitting to be compensated for by
stress values of the base metal shall apply to the design of the weld buildup. A plug of the same base material and of
the weld metal and the following factors shall be uniform thickness, u, not exceeding the smallest average
considered in the design: thickness on which the buildups will be permanently

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(a) the effects of three-dimensional shrinkage applied, shall be full-penetration welded around the
(b) the effects of flexibility, stress concentration, and opening and flush with the outside surface of the pressure

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section properties component. Alternatively, an equivalent volume of base
(c) stress concentrations from the pressure metal may be removed from the inside surface of the mock-
component internal surface configuration up by machining or grinding, without the need for welding
(d) the effects of differing thermal expansion in a closure plug.

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coefficients between the base and the weld metal 202-3.2.1.3 Buildup Thickness. Buildup section
(e) the effects of differing thermal mass of the buildup
thickness [deposit + base metal), represented by the
repair
dimension u and w in Figure 202-3-1, for the thinned area of
(f) the potential for creep degradation for service
the mock-up shall be not greater than 87.5% of the nominal

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temperatures above 340°C [650°F]
wall thickness. This is intended to provide a conservative
202- 3.1.3.3 Proof Test Qualification. As an thickness for the qualification of the buildup design.
alternative to the prequalified design or engineered
202-3.2.1.4 Burst Pressure. To qualify a repair design
design, a proof test qualification may be performed through a
for general application [on pressure components in the
satisfactory burst test mock-up. The details of the mock-
up configuration and considerations are in para. 202-3.2.
202- 3.2 Burst Test Procedures
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same orientation or at the same location on fittings], burst
pressure shall be not less than:
RP
202- 3.2.1 Proof Test Qualification Requirements. As
an alternative to the engineered design approach, a burst test
of a mock-up buildup may be performed to qualify a weld where
buildup design. D = outside diameter of the pressure component, mm
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(in.)
202- 3.2.1.1 General Requirements. A
P = minimum acceptable burst pressure, MPa (psi)
satisfactory mock-up burst test may be used to qualify the
S
weld buildup design for application in the same act = reported actual tensile strength, MPa (psi), of

orientation on the same type of item, and the same the base material tested
location on fittings, when the following conditions are t = minimum specified thickness (excluding
met: manufacturing tolerance) of base material tested,
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(a) The base metal is of the same P-No. and Group mm (in.)
number as the mock-up base material tested.
UD

202-3.2.1.5 Flexibility Analysis. If flexibility analysis

(b ) The specified minimum tensile strength of the
was required by the original construction code, the effect of
item does not exceed that of the mock-up base material
the weld buildup shall be reconciled with the original
tested.
analysis or qualified in accordance with para. 202-3.1.3.2.
(a) The average thickness of the buildup area[s) is
at least the thickness of the mock-up plug, u, in Figure 202- 3.2.2 Burst Testing Method
ST

202-3- 1.
(b) The overlap on the full thickness of base metal, B, WARNING: Hydrostatic burst testing has the potential to
is at least that of the mock-up. cause loss of life and damage to property. All tests shall be
(c) The transition angle at the outer edges of the thoroughly evaluated for safety and control of debris from
overlay, a, is not greater than that of the mock-up. component failure.
R

(d) The buildup surface is similar to or smoother

than that tested.
(e) The maximum axial dimension/diameter ratio, L/D,
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is not more than that tested.

(f) The maximum circumferential dimension/
diameter ratio, C/D, is not more than that tested.
(g) The nominal diameter is not less than one-half or
more than 2 times the diameter of mock-up tested.
(h) The nominal thickness/diameter ratio, t/D, is not
less than one-half or more than 3 times the t/D ratio tested.

12
 ASME PCC-2-2018

202-3.2.2.1 Pump Selection. The pump station used Grinding or wire brushing may be necessary to remove
for burst testing should be capable of exceeding the surface oxides or protective coatings.
maximum calculated burst pressure. The pump should be
202-4.2.2 Solvent Cleaning. Immediately prior to
capable of providing a minimum of 25% overpressure to
welding, the final weld surface should be thoroughly
allow for burst pressure variations from wall thickness
cleaned using a solvent, such as acetone, to remove any
tolerances, weld reinforcement, etc. In most cases, the actual
traces of oil or grease. This procedure will also help in
burst pressure will exceed the calculated value by a small removing traces of moisture. Surface contaminants may
margin.

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lead to porosity and other welding defects, which may
202-3.2.2.2 Burst Test Fittings and Gages. All adversely affect the welding quality. A clean surface will also
fittings, hoses, and gages shall be rated for a working assist in permitting more accurate nondestructive

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pressure equal to or greater than the pump rating. Fittings examination assessment of the pressure component wall
attached to the pressure component mock-up should be degradation.
threaded into the end bells of the mock-up and then seal
welded to prevent leakage. Gages shall be rated for working 202-4.2.3 Leakage Repair. All leakage shall be repaired
prior to performing the weld buildup repair. If sufficient

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pressures at or above the pump pressure rating and shall be
calibrated to a pressure standard, traceable to the National material is available, peening may be used to close off the
Institute of Standards and Technology (NIST), or equivalent, leakage and permit seal welding. Another option is
by a reputable laboratory. The expected burst pressure of application of a series of overlapping weld beads

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the component being tested shall fall within one-fourth to immediately adjacent to the leakage. Once sufficient
two-thirds of the gage rating, so as to be in the most accurate material is available, peen to close off the leakage and
portion of the gage measurement range. perform final seal welding.
202-4.2.4 Special Considerations. Seal welded repairs
202-4 FABRICATION
This section describes application methods and
techniques for applying weld buildups on degraded or O
conducted on-line, or to systems containing hazardous
materials, may require special considerations that are
outside the scope of this Article.
RP
thinning steel pressure components. This section should be
202-4.3 Weld Buildup Placement
considered as general requirements for weld building and
shall be used in conjunction with the requirements of the 202- 4.3.1 Mapping of Degraded Area. The area that is
applicable construction code or post-construction code. determined to be degraded below the allowable wall
thickness should be clearly mapped-out on the pressure
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202-4.1 Prerepair Inspection component surface, using a scribe or other suitable marking
Requirements technique.
202-4.1.1 Evaluation of Base Material. The material 202-4.4 Electrode Size and Filler
beneath the surface to be weld built up shall be evaluated to 202- 4.4.1 Weld Metal Requirements. The required
establish the average wall thickness and the extent and weld metal shall conform to para. 202-3.1.1.
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configuration of thinning to be reinforced by the weld

buildup. Consideration should also be given to the cause and 202- 4.4.2 Wall Thickness Determination. Prior to
rate of deterioration. (If the cause of the thinning is not known initiation of welding, the remaining wall thickness shall be
UD

or understoo d, then a materials engi neer should be consulted to determined to ensure that the proper electrode size is used
approve the repair techniques and procedures to ensure to prevent burn-through of the pressure component wall.
that the repair will not cause an unacceptable change in the 202-4.4.3 Minimizing Penetration. It is necessary to
deterioration mechanism.)
minimize penetration during the first layer, thus smaller
202-4.1.2 Volumetric Examination. The user shall
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diameter electrodes should be used. If in doubt about the

determine that cracking has not occurred prior to accuracy of the wall thickness, such as in the case of pitting,
commencing the repair. The area of the existing pressure the smallest possible electrode should be selected.
component, to which the weld buildup is to be applied,
should be volumetrically examined prior to performing the 202-4.4.4 Electrode Size. The electrode size
weld buildup. should not exceed the remaining base material wall
R

thickness.
202-4.1.3 Surface Examination. The entire surface, to
which the weld buildup is to be applied, shall be examined
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using appropriate NDE technique(s] to verify surface

quality prior to welding. Acceptance criteria shall be in
accordance with the applicable construction code or post-
construction code.

202-4.2 Prerepair Surface Preparation

202-4.2.1 General. The surface to be built up shall

be free from rust, scale, paint, coatings, or other
contaminants.

13
 ASME PCC-2-2018

202-4.4.5 Burn-Through. The potential for burn- 202- be initiated on the first layer. Welding
through and consequences thereof, shall be evaluated. parameters should provide as low of a heat input as possible
202-4.5 Welding Process and Techniques while maintaining fusion. This not only reduces the
potential for burn-through but also reduces the width of the
202- 4.5.1 Welding Procedure Qualification. finished heat-affected zone.
Buildup welding shall be performed using a qualified groove
welding procedure, in accordance with ASME BPVC, Section 202- 4.5.9.2 Initial Welding Pass. The
IX, or as required by the applicable construction code or first weld pass(es) should follow the outer perimeter of the

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post-construction code. weld buildup location to U (a) provide an outer gage for
202-4.5.2 Welder Qualification. Welders the welder.

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performing buildup welds shall be qualified in accordance (a) improve the heat-affected zone quality by
with ASME BPVC, Section IX, or as required by the applicable eliminating the potential for a final, untempered weld pass
construction code or post-construction code. on the base metal surface for carbon and low alloy steel
materials. After completion of the perimeter weld pass, the
202-4.5.3 Welding Processes. Typical welding first layer may be welded in accordance with the qualified

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processes for these repairs include, but are not limited to, weld procedure.
SMAW and GTAW.
202- 4.5.9.3 Su b se q u e n t W e l d i n g P a s se s .
202- 4.5.4 Wall Thickness Considerations.
Subsequent welding passes may be completed in a normal

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Pressure components with wall thickness less than the
fashion; however, care should be taken with the weld passes
diameter of the electrode should be depressurized before
at the edges of the buildup to maintain the edge angle, or
welding.
taper, to equal or less than that qualified. An edge angle of
202-4.5.5 Depressurization. Consideration should 30 deg is recommended and meets one of the provisions for
be given to depressurizing the system before welding. a prequalified design. The taper angle is important as it
Alternatively, appropriate in-service welding techniques
(e.g., as provided in API RP 2201) should be used. O
minimizes the stress intensifying effect of the buildup due to
the changes in surface geometry.
RP
202-4.5.6 Heat Treatment. Heat treatment shall be
202-4.5.9.4 Edge Taper Angle. The maximum
performed in accordance with the applicable construction
allowable edge taper angle is 45 deg.
code or post-construction code, or engineering design. Heat
treatments shall only be applied to equipment that is 202- 5 EXAMINATION
repaired while not in service. In some cases, heat treatment
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The inspections specified in paras. 202-5.1 through 202-

may be required to meet service conditions or process and
5.4 apply to weld buildup repairs.
may not be required by construction code (e.g., for H2S
cracking). 202- 5.1 Surface Examination
202- 4.5.7 Temper Bead Technique. Temper bead The completed weld buildup shall be examined using the
techniques, as permitted in the applicable post-construction liquid penetrant or magnetic particle method and shall
satisfy the surface examination acceptance criteria of the
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codes, may be used on carbon steel or low alloy steel to

avoid the need for high temperature heat treatments. Avoid applicable construction code or post-construction
use of temper bead methods where process or service code.
UD

conditions mandate use of heat treatment (e.g.. H2S, HCN, 202- 5.2 Buildup Thickness
HF).
Adequate wall thickness of weld buildup and relevant
202-4.5.8 Bead Overlap. A bead overlap of existing base metal shall be verified by ultrasonic thickness
approximately 50% should be maintained to reduce the measurement.
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potential for burn-through and to assist in obtaining proper

bead placement In some cases, wastage may have 202-5.3 Volumetric Examination
progressed to the point where there is risk of burning When volumetric examination is required by the
through the component when depositing the first layer(s). applicable construction code or post-construction code, the
To prevent burn-through in such situations, the first bead full volume of the finished buildup, excluding the tapered
should be deposited where the remaining thickness is edges, but including the volume of base metal required for
R

greater, then subsequent beads should be overlapped to the design life of the buildup, shall be examined by either the
step across the thinner area. ultrasonic or radiographic method. The repair shall satisfy
FO

202-4.5.9 Welding Techniques. The techniques the acceptance criteria for girth welds of the applicable
specified in paras. 202-4.5.9.1 through 202-4.5.9.4 may be construction code or post
used.
4.5.9.1 Considerations Prior to Welding. Once
the area to be repaired has been mapped and the pressure
component surface cleaned, welding may

14
 ASME PCC-2-2018

construction code, if there are no acceptance criteria for 202-6.3 Insulation and Coating
structural buildups, butters, or cladding. All testing and examinations shall be performed
prior to application of insulation or coatings.
202-5.4 Surface Finish
202-7 REFERENCES (18)
Grinding and machining of the as-welded buildup surface
The following is a list of publications referenced in
may be used to improve the surface finish for such
this Article. Unless otherwise specified, the latest
examinations, provided the buildup thickness is not
edition shall apply.
reduced below design requirements.
API 510, Pressure Vessel Inspection Code:
202-6 TESTING Maintenance Inspection, Rating, Repair, and Alteration
202-6.1 Pressure Testing API 570, Piping Inspection Code: Inspection, Repair,
Alteration, and Rerating of In-Service Piping Systems
If the pressure component can be isolated for pressure API RP 2201, Safe Hot Tapping Practices in the
testing, all repair locations shall be pressure tested if Petroleum & Petrochemical Industries
required by the applicable post-construction code. Special Publisher: American Petroleum Institute (API), 1220 L
safety precautions shall be taken when performing Street, NW, Washington, DC 20005 (www.api.org)
pneumatic testing to minimize the risk of brittle fracture.
ASME Boiler and Pressure Vessel Code, Section IX —
202-6.2 Volumetric Examination in Place of Pressure Welding, Brazing, and Fusing Qualifications Publisher:
Testing The American Society of Mechanical Engineers
(ASME), Two Park Avenue, New York, NY 10016-5990
Volumetric nondestructive examination may be
(www.asme.org)
performed in place of pressure testing, when pressure
testing is not practical. Leak testing may be required to National Board Inspection Code, NB-23 Publisher:
satisfy post-construction code requirements. National Board of Boiler and Pressure Vessel
Inspectors (NBBI), 1055 Crupper Avenue, Columbus,
OH 43229 (www.nationalboard.org)

15
 ASME PCC-2-2018

Article 209
Alternatives to Post weld Heat Treatment

209-1 DESCRIPTION 209-2.3 Suitability Tests

209-1.1 General Considerations Tests to demonstrate suitability of the repair procedure
may be needed if service conditions are subject to hydrogen
This Article addresses alternatives to post weld heat
embrittlement or at temperatures in the creep range or if
treatment for repair welds. Under certain service
the alternative is being considered for "on-stream" repairs
conditions, PWHT of a repair weld in accordance with
or "hot tapping” on piping systems. Testing may be in
the construction code can be inadvisable or impractical.
accordance with owner criteria, the construction code or
An example of such a condition would be a penetration
post-construction code.
or embedment surrounded by reinforced concrete or
liquid media that could be damaged or create an unsafe 209-2.4 Resistance to Service Conditions
condition by application of PWHT temperatures. In If resistance to hydrogen or sulfide or stress cracking is
addition, inspection of pressure vessels, tanks, and a service requirement, test evidence shall be developed
piping which have been in service can reveal defects or appropriate to the risk involved to show that a maximum
damage that require weld repair but not redesign of the hardness in weld metal and heat-affected base metal is not
item containing the defect. The original construction exceeded when qualifying a specific Welding Procedure
code or owner can require post weld heat treatment Specification (WPS). Maximum hardness shall be as
(PWHT). required by the owner, the construction code or post-
construction code.
209-1.2 Factors Affecting Selection
209-2.5 Residual Stress Reduction
(a) Post weld heat treatment is applied to ferritic
welds and welded components to reduce high levels of If reduction of residual stresses in weldments is required
residual stress, provide tempering to reduce hardness, for successful operation in services subject to stress
and to diffuse hydrogen. corrosion cracking (e.g., where amines, caustics, or
(b) Time and temperatures for PWHT are specified carbonates are involved), then alternatives to post weld
with respect to individual types of material and are heat treatment shall be evaluated and determined to be
selected to be performed below the lower (critical) acceptable for the intended service prior to use.
transformation temperature of the material. 209-2.6 Altering Material Properties
(c) Alternatives to post weld heat treatment can
Some steels are susceptible to metallurgical change such that loss
involve application of elevated preheat and/or
of notch toughness can occur in the weld heat-affected zone
implementation of specific welding techniques, bead
and in the base metal. Weld metal can also experience a loss
sequencing, and increased control of the welding
of toughness and/or strength when subjected to PWHT. In
process.
other steels, intergranular cracking (often called reheat or
209-2 LIMITATIONS stress relief cracking) can occur in the weld heat-affected
zone during PWHT while excessive post weld heat
209-2.1 Post-Construction Code treatment (temperature and hold times) can also cause loss
Part 1 of this Standard, "Scope, Organization, and of strength in the weld and/or base metal.
Intent," contains additional requirements and
limitations. This Article shall be used in conjunction
with Part 1.

209-2.2 Methods
Only methods that are recognized in an applicable
construction code or post-construction code, qualified,
or as justified through performance of a risk assessment
evaluation, shall be used.

47
 ASME PCC-2-2018

Table 209-4.1-1 Summary of Post weld Heat Treatment Requirements and Potential Alternatives
Code Location
API 510 Paragraph 7.3.2
ASME BPVC, Section I PW-39, PW-40
ASME BPVC, Section III-NB/NC/ND/NE/NF/ Although the Subsections of ASME BPVC, Section III have rules for PWHT and
NG/NH alternatives (e.g., NB-4622), nuclear components and systems are unique in that they
have their own specific post-construction code for qualification, repair, and examination;
ASME BPVC, Section XI (see below)
ASME BPVC, Section VIII, Division 1 UCS-56, UHT-56, UHA-32, UHA-105, UNF-56, UCL-34, ULW-26, ULT-56
ASME BPVC, Section VIII, Division 2 AF-402, AF-420, AF-550, AF-630, AF-753, AF-7S4, AF-820, AT-115, Appendix 26
(26-200]
ASME BPVC, Section VIII, Division 3 KF-400, KF-630, KF-830
ASME BPVC, Section IX QW-290
ASME BPVC, Section XI IWA-4600
ASME B31.1 Paragraph 132.3, Tables 132 and 132.1
ASME B31.3 Paragraph 331.2.2, Table 331.1.1
AWS D1.1 Paragraphs 5.8.2 and 5.8.3
AWS D10.8 Paragraph 6 and Table 4
AWS D10.10 Paragraph 13.2
NBIC; NB-23 Part 3

209-3 DESIGN 209-4.2 Alternative Welding Methods

209-3.1 Dissimilar Metal Welds 209-4.2.1 Temper Bead Welding. Tempering of weld
deposits may be accomplished by implementing special
Welding involving dissimilar materials shall be weld sequences and techniques. Controlled deposition
separately evaluated unless specifically addressed by the techniques such as temper bead welding, for example, are
applicable post-construction code. Guidance in this area is offered in many construction or post-construction codes as
provided in Method 5, NBIC, of ANSI/NB-23. an alternative to postweld heat treatment.
209-3.2 Procedures 209-4.2.2 Satisfying Properties. The method used shall
produce weldments that satisfy mechanical and corrosion
Requirements for implementing alternatives to post
properties in accordance with the applicable construction
weld heat treatment should be outlined in specific
code or post-construction code.
documented instructions that are accompanied by a
qualified Welding Procedure Specification. 209-4.2.3 Absence of Code Rules. When no
construction code or post-construction code is specified,
209-4 FABRICATION the rules in API 510, 7.2.3; ASME BPVC, Section IX, QW-290;
209-4.1 Application of Elevated Preheat or ANSI/NB-23, Part 3, may be used as rules for controlled
deposition welding techniques.
Many codes of construction or post-construction codes
permit use of elevated preheat as an alternative to 209-4.3 Requiring Additional Methods
performing post weld heat treatment Examples of Application of alternative methods may require that
alternatives can be found in API 510; ASME BPVC, Section I reliable preheat maintenance techniques, low hydrogen
(PW-39); ASME BPVC, Section VIII; ASME B31.1 (Table welding consumables, and optimum materials storage
132); and ANSI/NB-23. Criteria are expressed as a function practices be implemented.
of base metal specification, type, grade, and thickness. Table
209-4.1-1 lists a variety of PWHT methods and alternates 209-5 EXAMINATION
from potential applicable codes. The table is not all- Examination shall be in accordance with the applicable
inclusive and should be used as a guide for selecting an construction code or post-construction code.
alternative to post weld heat treat for work that is to be
conducted with a specific construction code or 209-6 TESTING
postconstruction code. Testing shall be in accordance with the applicable
construction code or post-construction code.

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 ASME PCC-2-2018

(18) 209-7 REFERENCES ASME Boiler and Pressure Vessel Code, 2007 Edition,
The following is a list of publications referenced in this Section VIII, Rules for Construction of Pressure Vessels;
Article. Unless otherwise specified, the latest edition shall Divisions 1, 2, and 3 ASME Boiler and Pressure Vessel
apply. Code, 2007 Edition, Section IX, Welding and Brazing
Qualifications ASME Boiler and Pressure Vessel Code, 2007
ANSI /NB-23-2007, National Board Inspection Code Edition, Section XI, Rules for Inservice Inspection of
Publisher: American National Standards Institute (ANSI), 25 Nuclear Power Plant Components ASME B31.1-2007,
West 43rd Street, New York, NY 10036 (www.ansi.org) Power Piping ASME B31.3-2006, Process Piping Publisher:
API 510, Pressure Vessel Inspection Code: Maintenance The American Society of Mechanical Engineers (ASME),
Inspection, Rating, Repair, and Alteration; Revision 06, 2006 Two Park Avenue, New York. NY 10016-5990
Publisher: American Petroleum Institute (API), 1220 L (www.asme.org)
Street, NW, Washington, DC 20005 (www.api.org) AWS D1.1/D1.1M-2006, Structural Welding Code — Steel
ASME Boiler and Pressure Vessel Code, 2007 Edition, AWS D10.8-1996, Recommended Practices for Welding
Section I — Rules for Construction of Power Boilers ASME Chromium-Molybdenum Steel Piping and Tubing AWS
Boiler and Pressure Vessel Code, 2007 Edition, Section III, D10.10-1999, Recommended Practices for Local Heating of
Rules for Construction of Nuclear Facility Components; Welds in Piping and Tubing Publisher: American Welding
Subsections NCA, NB, NC, ND, NE, NF, NG, and NH Society (AWS), 8669 NW 36 Street, No. 130, Miami, FL
33166 (www.aws.org)
Recommended Practices for Local Heating of Welds in
Pressure Vessels, WRC Bulletin 452, June 2000.

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 ASME PCC-2-2018

Article 210
In-Service Welding onto Carbon Steel Pressure Components or
Pipelines

210-1 DESCRIPTION The likelihood of developing microstructures

This Article addresses the requirements and precautions susceptible to hydrogen cracking can be high because in-
associated with welding onto pressure components or service welds tend to have accelerated cooling rates due to
pipelines while the system is still in operation. In- service the ability of the pressure components or pipeline contents
pressure components or pipelines include pressure to pull heat from the weld region. The chance of developing
equipment and piping and are defined as systems in which a crack-susceptible microstructure can be reduced by using
the contents may or may not be pressurized and/or flowing welding procedures that overcome the cooling effect of the
but affect the way the weld cools. This Article is intended to pressure components or pipeline contents or by altering the
be used in conjunction with Part 2 of this Standard or pressure components or pipeline operating conditions
another applicable construction code or post-construction during in-service welding. Such welding procedures include
code. using sufficiently high heat input levels or by using specific
There are two primary concerns when performing in- weld deposition sequences. The most common in-service
service welding. The first concern is "burn-through," also welding practices used to reduce hydrogen cracking
referred to as "blowout. “A burn-through occurs when the concerns incorporate both a low-hydrogen welding process
unmelted base material under the weld pool loses the and a welding procedure that reduces the susceptibility of
ability to contain the contents of the pressure components forming a crack-susceptible microstructure. The use of
or pipeline allowing the contents to be expelled. Welding preheat is another technique that is commonly used to
onto pressure components or pipelines with thin walls (e.g., reduce the susceptibility of forming a crack-susceptible
4.8 mm (0.188 in.) or less] is possible as long as precautions microstructure but it may be difficult to apply to in-service
are taken. Such precautions include controlling the heat welding applications because of the ability of the pressure
input or penetration of the welding process and using components or pipeline contents to cool the pipe wall
smaller diameter electrodes [e.g., 2.4 mm (0.094 in.)] when especially for thin-walled applications. The cooling effect of
the wall thickness is less than 6.4 mm (0.250 in.). Safety the pressure components or pipeline contents can interfere
aspects and contingency planning aspects for an occurrence with achieving the proper preheating temperature.
of burn-through should be planned for in accordance with Successful application of in-service welding procedures
company practices, industry standards (e.g., API requires a balance between the probability of burn- through
Recommended Practice 2201], or post-construction code. and reducing the probability of hydrogen cracking. For
The second concern is hydrogen cracking. Hydrogen example, when welding onto a pipeline less than 6.4 mm
cracking occurs when tensile stresses are acting on the (0.250 in.) thick it may be necessary to reduce the welding
weld, hydrogen is present in the weld and, when the weld heat input to lower the probability of burn-through;
solidifies, the resultant weld microstructure is crack however, the lower welding heat input could result in a
susceptible. If any of the three conditions is eliminated or weld microstructure that is susceptible to hydrogen
reduced below a threshold level, then hydrogen cracking cracking. When the maximum required welding heat input
will not occur. Tensile stresses can always be assumed due to eliminate the probability of burn-through is lower than
to the shrinkage of the weld upon cooling. Hydrogen, the minimum required heat input to protect against
typically, cannot be eliminated but can be reduced by using hydrogen cracking then alternative precautions need to be
proper low hydrogen welding processes such as shielded taken (e.g., welding procedure that included a temper bead
metal arc welding with EXX18 or EXX15 type electrodes. deposition sequence).
Crack-susceptible microstructures typically have high
microstructure hardness and are controlled by the carbon
equivalence of the material and the rate at which the weld
cools.

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 ASME PCC-2-2018

210-2 LIMITATIONS 210-.6 Operating Flow

210-2.1 Additional Requirements An adjustment in flow during in-service welding may
increase hydrogen cracking risk (e.g., increase flow] or
Part 1 of this Standard, "Scope, Organization, and Intent,"
burn-through risk (e.g., reduce flow). An adjustment in flow
contains additional requirements and limitations. This
should be addressed prior to in-service welding.
Article shall be used in conjunction with Part 1.

210-2.2 Piping and Pipeline Modifications 210-2.7 Post weld Heat Treatment (PWHT)
PWHT is difficult to perform while the pressure
This Article is limited to application of in-service welding.
components or pipeline system remains in service. If PWHT
Though this Article covers in-service welding aspects, not all
is required, the owner shall address all additional concerns
aspects of pressure components or pipeline modifications
to assure the welding and subsequent PWHT will be
that are performed to modify or expand a piping system
completed in a safe manner. If this cannot be achieved, then
(e.g., the hot tapping procedure that may follow the in-
an alternative repair method shall be evaluated.
service weld) are covered by this Article. This Article should
be used in conjunction with another applicable construction 210-3 DESIGN
code or post-construction code that deals with the specifics
of the pressure components or pipeline modification (e.g., 210-3.1 In-Service Fillet Weld Procedure
for hot tapping, refer to API Recommended Practice 2201). An in-service fillet weld procedure is defined as a
procedure that is used to join additional material onto the
210-2.3 Pressure Components or Pipeline
in- service pressure components or pipeline to reinforce a
Material
damaged area (e.g., full encirclement sleeves and patch plate
This Article shall be limited to in-service welding onto all repairs] or to facilitate a modification (e.g., proprietary full
carbon steel pressure components or pipelines. This Article encirclement hot-tap fitting). The fillet weld shall be
excludes welding onto stainless steels, alloyed steels (e.g., designed in accordance with an applicable construction
Cr-Mo), or nonferrous materials. code or post-construction code.

210-2.4 Pressure Components or Pipeline 210-3.2 In-Service Attachment Weld

Contents Procedure
Before performing any in-service welding, the owner An in-service attachment weld procedure is defined as a
shall evaluate the effect that in-service welding could have procedure that is used to make a modification to existing
on the contents of the pressure components or pipeline pressure components or pipeline and usually includes a
system (e.g., combustion, explosion, and increased groove weld joint the attachment weld shall be designed
susceptibility to corrosion or embrittlement). In- service under one of the following two criteria:
welding should only be performed on pressure components (a) If the attachment provides adequate reinforcement
or pipelines where the evaluation indicates that there is not in accordance with an applicable construction code or post-
a significant risk associated with potential metallurgical construction code, no further reinforcement is required.
degradation or chemical reaction from the in-service (b) If the attachment does not provide adequate
welding process and not a significant risk of chemical reinforcement in accordance with an applicable
reaction in the process fluid as a result of potential contact construction code or post-construction code, additional
with high metal temperatures. reinforcement is required.

210-2.5 Operating Pressure 210-3.3 In-Service Weld Metal Buildup

Procedure
An adjustment in the pressure during in-service welding
may not be required from a welding perspective but may be An in-service weld metal buildup procedure is defined as
necessary to increase the safety of the welder if a burn- a procedure that is used to deposit weld metal onto the
through does occur. Safety aspects and contingency surface of the pressure components or pipeline to reinforce
planning aspects for an occurrence of a burn- through a thinned area (e.g., metal loss due to corrosion or erosion).
should be planned for in accordance with company The weld metal buildup shall be designed in accordance
practices, industry standards (e.g., API Recommended with an applicable construction code or post-construction
Practice 2201), or post-construction code. code.

51
 ASME PCC-2-2018

210-4 FABRICATION is specified separately for the in-service pressure

components or pipeline and the second base material (e.g.,
210-4.1 Welding Procedure Qualification: full- encirclement sleeve or attachment material). An in-
Welding service welding procedure qualified on a specific carbon
When approved by the welding engineer or welding equivalent material may also be adequate for lower carbon
inspector, a welding procedure qualified to the applicable equivalent materials assuming the cooling potentials are the
new construction code or post-construction code may be same. A procedure qualified on lower carbon equivalent
used for in-service welding applications. However, the material can be used in a repair application on a higher
welding procedures that are to be used for welding onto in- carbon equivalent material provided that the cooling
service pressure components or pipeline shall address the potential of the repair application is less than the cooling
probability of burn-through and hydrogen cracking. When potential of the qualified procedure and there is no increase
required by the welding engineer or welding inspector, the in hydrogen cracking susceptibility. The carbon equivalent
welding procedure shall be qualified using the set-up should be calculated using the following formula with the
outlined in Mandatory Appendix elements expressed in weight percent amounts:
208- 1 and the testing in para. 210-4.2. The essential
variables for the welding procedure qualification shall be in
accordance with an applicable construction code or
postconstruction code and should include the in-service
welding essential variables listed in para. 210-4.1.1. 210-4.1.1.4 Welding Process. A change in the
WARNING: Materials that have high carbon equivalent welding process shall require requalification.
values (e.g., > 0.45) or experience severe weld cooling rates 210-4.1.1.5 Welding Consumable. An increase in the
(i.e., high cooling potential) may require special diffusible hydrogen level of the welding consumable or a
precautions. Such precautions may include but are not change in the electrode type as defined by ASME BPVC,
limited to temper bead welding sequence or applying a
Section IX, Table QW-432, or another applicable
preheat step prior to in-service welding.
construction code or post-construction code, shall require
210-4.1.1 In-Service Welding Essential Variables. The requalification.
in-service welding essential variables are specific 210-4.1.1.6 Heat Input. The heat input range is
requirements for in-service welding that should be used in determined by the weld procedure qualification and is the
addition to the essential variables from an applicable range that will produce a weld that will not burn through
construction code or post-construction code. and has a low likelihood of producing a crack-susceptible
210-4.1.1.1 Weld Type. In-service welds shall be microstructure. A change in the heat input range shall
grouped into one of the following three types and qualified require requalification. The heat input should be calculated
separately: in accordance with ASME BPVC, Section IX, QW-409.1(a) or
(a) in-service fillet weld QW-409.1(b), or another applicable construction code or
(b) in-service attachment weld post-construction code.
(c) in-service weld metal buildup (a) An increase in the heat input over the range specified
in the in-service procedure qualification or specified in the
210-4.1.1.2 Cooling Potential. The rate at which a in-service welding procedure shall be evaluated for burn-
weld cools, or cooling potential, is an essential variable [e.g., through risk. The probability of burn-through should be
cooling time from 800°C to 500°C (1,472°F to 932°F) (sec) evaluated experimentally, by computer simulation, or a
or cooling rate at 556°C (1,000°F) (°/sec)]. An increase in combination of these methods.
the cooling potential of the in- service pressure component (b) A decrease in the heat input below the range
or pipeline greater than the cooling potential used during specified in the in-service procedure qualification or
the qualification of the welding procedure requires specified in the in-service welding procedure shall require
requalification. The cooling potential may be determined by requalification to determine the probability of hydrogen
direct measurement, calculation, computer models, or a cracking susceptibility. Hydrogen cracking susceptibility
combination of these methods. should be evaluated using the test outlined in para. 210- 4.2.
210-4.1.1.7 Welding Current. A change in the range of
NOTE: In the procedure qualification, wall thickness is not an welding current used in the procedure qualification or
essential variable but is directly related to the cooling potential of specified in the welding procedure shall require
the pressure components or pipeline, which is an essential
requalification.
variable.

210-4.1.1.3 Carbon Equivalence. The in-service welding

procedure should be grouped according to carbon
equivalence of the material. Carbon equivalence

52
 ASME PCC-2-2018

Table 210-4.2.1-1 Type and Number of Test Specimens Required for an In-Service Welding Procedure Qualification

Tests
Wall Thickness In-Service Weld Type
Face Bend Side Bend Nick-Break Metallography Hardness
4 -- 4 2 2
12,7 mm Fillet
Attachment 4 -- 4 2 2
(0.500 in.) Weld metal buildup
4 -- -- 2 2
4 -- 4 2 2
>12.7 mm Fillet
(0.500 in.) Attachment 4 -- 4 2 2
Weld metal buildup
2 2 2 2 2

210-4.1.1.8 Post weld Bakeout. A reduction of construction code and should include the in-service
the temperature or time of the application of a post weld welding essential variables listed in para. 210-4.1.1.
bakeout shall require requalification. When specified, the 210-4.2.1 Destructive Test Methods. In-service
minimum soaking temperature and time shall be specified. welding procedure test samples shall be taken from the
Any potential effect the post weld bakeout has on the procedure qualification weld coupon as specified in para.
pressure components or pipeline contents shall be 210-4.2.2. The procedure shall be qualified by successful
evaluated. completion of the tests specified in paras. 210-4.2.1.1
210-4.1.1.9 Preheat. A reduction of the through 210-4.2.1.4. The number of tests for each in-service
temperature or time of application of a preheat welding procedure is given in Table 210-4.2.1-1. Two
requirement shall require requalification. When specified, procedure qualification weld coupons should be fabricated
the minimum soaking temperature and time shall be if there is not enough material available for all of the test
specified. Any potential effect the preheat requirement has samples in one procedure qualification. The destructive test
on the pressure components or pipeline contents shall be specimens shall be machined in accordance with AWS B4.0
evaluated. or other applicable standard.
210-4.1.1.10 Hydrogen Bakeout. A change in the 210-4.2.1.1 Macro-Section Test. The macro-
temperature or time of application of the hydrogen bakeout section test samples shall be removed and machined using
procedure shall require requalification. Any potential effect nonthermal methods. The macro-section test sample
the hydrogen bakeout requirement has on the pressure should be in accordance with ASTM E3 or another
components or pipeline contents shall be evaluated. equivalent document to give a clear representation of the
weld region. Visual examination of the macro-section test
210-4.1.1.11 Surface Bead Placement. Any change in samples shall show
weld bead position or deposition sequence of the in- service (a) complete fusion
welding procedure shall require requalification. (b) no cracks
210-4.2 Weld Procedure Qualification: Testing (c) no undercut exceeding 0.8 mm (0.031 in.) or 10% of
the simulated in-service pressure components or pipeline
Welding procedures that are to be used to weld onto in-
wall thickness, whichever is smaller
service pressure components or pipelines shall address the
(d) for fillet welding procedures only, the fillet weld
probability of burn-through and hydrogen cracking
leg lengths are at least equal to the leg length specified in
susceptibility. The probability of burn-through should be
the welding procedure or other applicable process control
evaluated experimentally, by computer simulation, or a
document
combination of these methods. Hydrogen cracking
susceptibility should be evaluated by destructive and 210-4.2.1.2 Hardness Test. The hardness test
nondestructive testing. When approved by the welding samples shall be tested in accordance with ASTM E384 or
engineer or welding inspector, a welding procedure another equivalent document. A minimum of five Vickers
qualified to the applicable new construction code or hardness indents, using a 10-kg load, shall be made in the
postconstruction code may be used for in-service welding coarse-grained heat-affected zone of the weld toe in
applications. When required by the welding engineer or accordance with Figure 210-4.2.1.2-1. The macro-section
welding inspector, the welding procedure shall be qualified test samples may be used for the hardness test samples
using the set-up outlined in Mandatory Appendix 210-1 and after the metallographic analysis has been completed.
testing in para. 210-4.2. The essential variables for the 210-4.2.1.3 Nick-Break Test. Nick-break test samples
welding procedure qualification shall be in accordance with shall be removed and machined using nonthermal
an applicable construction code or post methods, and shall be tested according to

53
 ASME PCC-2-2018

GENERAL NOTES:
(a) Indents are spaced 0.2 mm (0.008 in.) from fusion line and 0.6 mm (0.024 in.) apart Initial indent is located 0.6 mm
(0.024 in.) from weld toe.
(b) The figure is not to scale.

AWS B4.0 or another equivalent document. Visual equivalent document.1 The bend test samples should
inspection of the nick-break test sample fracture surfaces be bent in a guided-bend test jig or equivalent equipment.
shall show For face bends, the bend test sample shall be placed with the
(a) complete fusion. face of the weld opposite the mandrel (Figure 210- 4.2.1.4-
(b) no single pore exceeds 1.6 mm (0.063 in.) in size, and 1). The weld reinforcement should be removed prior to
the combined area of all pores does not exceed 2% of the bending. The remaining weld should not exceed 1.6 mm
exposed fracture surface area. (0.063 in.). The bend test sample shall be bent until the
(c) no slag inclusion exceeds 0.8 mm (0.031 in.) in depth curvature of the bend test specimen is approximately a U-
and 3.2 mm (0.125 in.) or one-half the nominal pipe wall shape (Figure 210-4.2.1.4-2), Visual inspection of the bend
thickness in length, whichever one is smaller. The distance test specimens shall show
between adjacent slag inclusions shall not be less than 12.7 (a) no cracks or other weld flaws exceeding 3.2 mm
mm (0.500 in.). (0.125 in.) or one-half the nominal pipe wall thickness,
(d) fisheyes, as defined in AWS A3.0, should not be cause whichever is smaller, in length are present in the weld or
for rejection. fusion zone
210-4.2.1.4 Face or Side Bend Test. The bend test (b) cracks that originate from the edge of the bend test
samples shall be machined using nonthermal methods, and specimen that are less than 6.4 mm (0.250 in.) in length in
shall be tested according to AWS B4.0 or another any direction should not be cause for rejection unless an
obvious weld flaw is present

54
ASME PCC-2-2018

55
 ASME PCC-2-2018

210-4.2.2 Sample Location. The locations of the in- construction code or post-construction code with the
service welding procedure test samples for a fillet weld additional ability to locate weld flaws including hydrogen
should be taken from equally spaced intervals around the cracking since it is a major concern for in-service welding
procedure qualification weld coupon as shown in Figure under the service conditions (e.g., operating temperature).
210-4.2.2-1. The locations of the in- service welding The acceptance criteria for the NDE examination shall be in
procedure test samples for an attachment weld should be accordance with an applicable construction code or post-
taken from equal spaced intervals around the procedure construction code. If welding was done to repair a service
qualification weld coupon with samples taken from both the induced defect, the NDE method that was used to detect the
crotch and saddle portions of the weld as shown in Figure defect shall be used to verify removal of the defect.
210-4.2.2-2. The locations of the in-service welding When NDE procedures are applied after in-service
procedure test samples for a weld buildup weld coupon welding, special procedures may be necessary where the
should be taken as shown in Figure 210-4.2.2-3. components are operating at temperatures significantly
above ambient.
210-4.3 Welder Performance Qualification
Welders that are to perform in-service welding onto
210-5.2 Examination Time
pressure components or pipelines shall demonstrate the When hydrogen cracking is a concern, in-service welds
ability to deposit welds that produce microstructures that should be examined 24 hr. to 72 hr. after welding has been
are not crack susceptible and/or avoid burning through the completed.
pressure component or pipeline. This may be demonstrated
by successfully depositing an in- service weld or by 210-6 TESTING
qualifying a welder using the set-up detailed in Mandatory Testing should be completed in accordance with an
Appendix 210-1 and testing requirements outlined in para. applicable construction code or post-construction code. If
210-4.2. hydrotesting of a hot tapping component after installation
210-5 EXAMINATION 210-5.1 NDE is contemplated, the user is advised to consider the
210-5.1 NDE temperature of the operating component in order to avoid
The in-service weld, made in the field, shall be examined having the test fluid flash to steam.
after welding has been completed. The method of
examination shall be in accordance with an applicable

56
ASME PCC-2-2018

57
 ASME PCC-2-2018

GENERAL NOTES:
(a) SB = Side bend test sample; FB = face bend test sample; MS = Metallographic test sample
(b) The figure is not to scale

(18) 210-7 REFERENCES API 579-1/ASME FFS-1, Fitness-For-Service

The following is a list of publications referenced in API Standard 1104, Welding of Pipelines and Related
this Article. Unless otherwise specified, the latest Facilities
edition shall apply. Publisher: American Petroleum Institute (API), 1220 L
Street, NW, Washington, DC 20005 (www.api.org)
AGA Pipeline Repair Manual, December 31, 1994
ANSI/AWS A3.0, Standard Definitions; Including Terms for
Publisher: American Gas Association (AGA), 400
Adhesive Bonding, Brazing, Soldering, Thermal Cutting,
North Capitol Street NW, Suite 450, Washington, DC and Thermal Spraying
20001 (www.aga.org)
ANSI/AWS B4.0, Standard Methods for Mechanical Testing
API Recommended Practice 2201, Safe Hot Tapping Welds
Practices in the Petroleum & Petrochemical ANSI/NB-23-2007, National Board Inspection Code
Industries API Recommended Practice 579-1

58
 ASME PCC-2-2018

Publisher: American National Standards Institute (ANSI), ASTM E3, Standard Practice for Preparation of
25 West 43rd Street, New York, NY 10036 Metallographic Specimens
(www.ansi.org) ASTM E384, Standard Test Method for Micro indentation
Hardness of Materials
ASME B31.1, Pressure Piping
Publisher: American Society for Testing and Materials
ASME B31.3, Process Piping
(ASTM International), 100 Barr Harbor Drive, P.0. Box
ASME B31.4, Pipeline Transportation Systems for Liquid
Hydrocarbons and Other Liquids ASME B31.8, Gas C700, West Conshohocken, PA 19428-2959
(www.astm.org)
Transmission and Distribution Piping
Systems CSA Standard Z662, Oil and Gas Pipeline Systems
ASME Boiler and Pressure Vessel Code, 2007 Edition, Publisher: Canadian Standards Association (CSA), 178
Section IX, Welding and Brazing Qualifications; Article II — Rodale Boulevard, Toronto, Ontario M9W 1R3, Canada
Welding Procedure Qualifications; Article III — Welding (www.csagroup.org)
Performance Qualifications Publisher: The American
Society of Mechanical Engineers (ASME), Two Park
Avenue, New York, NY 10016-5990 (www.asme.org)

59
 ASME PCC-2-2018

Mandatory Appendix 210-1

In-Service Welding Procedure/Welder Performance
Qualification Setup

The intent of producing a simulated in-service welding backing because water has been shown to cool welds faster
procedure qualification is to make welds that will be more than any other cooling medium. It is important to note that
likely to produce hydrogen cracking during the using water as the cooling medium may make the welding
qualification than in the field. This can be done by making procedure overly conservative to the point of making it
welds on higher carbon equivalent carbon steel, by using a impossible to successfully qualify the weld coupon.
higher cooling potential, or by incorporating both variables The in-service procedure qualification coupon should
to have a more conservatively qualified procedure. have sufficient length to remove all of the required test
The simulated in-service setup used for the in-service specimens. More than one assembly may be used if all the
procedure qualification can be any applicable joint required specimens cannot be removed from a single
configuration, but it is imperative that the in-service assembly. The cooling medium should be circulated
procedure qualification weld coupon be more susceptible to through the test assembly prior to welding. The simulated
hydrogen cracking. It is good practice to simulate the actual in-service setup should be prepared as follows:
field weld that will be made using the in-service welding (a) The simulated in-service setup for an in-service fillet
procedure. It is common for the in-service production weld should be prepared in a manner similar to Figure 210-
qualification weld to be made using a higher carbon 1-1 or an alternative position that would
equivalent carbon steel pipe with water

Figure 210-1-1 Procedure and Welder Qualification Test Assembly for an In-Service Fillet Weld

GENERAL NOTE: The longitudinal weld seam is not considered an in-service weld unless the longitudinal seam weld fuses to
the simulated in- service pipe.

60
 ASME PCC-2-2018

Figure 210-1-2 Procedure and Welder Qualification Test Assembly for an In-Service Attachment Weld

simulate the in-service welding application. The sleeve (b) The simulated in-service setup for an in-service
should have a close fit to the carrier pipe unless a special weld metal buildup weld should be prepared in a manner
design sleeve fitting is to be qualified. The sleeve similar to Figure 210-1-1 but without using the sleeve. The
longitudinal groove welds should be welded prior to the in- weld will be deposited directly onto the pipe wall. It is
service fillet welds to improve fit-up [see Note to Figure common to mechanically remove a specified amount of wall
210-1-1]. to simulate corrosion loss. The probability of burn-through
(a) The simulated in-service setup for an in-service shall be evaluated before weld metal buildup is performed
attachment weld should be prepared m a manner similar to using the qualified procedure in the field.
Figure 210-1-2 or an alternative position that would After completion of the procedure qualification
simulate the in-service welding application. The tack weld, the cooling medium shall continue until the entire
welds should be ground to assure complete fusion along the assembly has achieved a uniform equilibrium temperature.
entire length of the weld. No test samples shall be taken
from the tack locations.

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 ASME PCC-2-2018

Article 211
Weld Buildup, Weld Overlay, and Clad Restoration

overlay or cladding. The original cladding could have been

211- 1 DESCRIPTION applied by methods such as roll bonding or explosion
bonding.
211- 1.1 Introduction 211-1.5.4 Back Cladding. Back cladding refers to the
This Article addresses the repair and restoration by weld application of corrosion resistant weld metal on a carbon
buildup or weld overlay of carbon steel base metal, low steel or low alloy steel weld in clad material that has been
alloy steel base metal, and corrosion resistant cladding or repaired.
weld overlay on internal surfaces of pressure vessels and 211-1.5.5 Effective Depth. The depth below the
piping that have experienced wall thinning.
finished weld surface at which weld metal chemical analysis
211- 1.2 Scope is performed. For the purpose of this Article, the effective
Repairs to weld overlay or cladding can involve depth is as defined in ASME BPVC, Section IX, Figure QW-
replacement of the entire thickness of the cladding or weld 462.5(a).
overlay, or a partial thickness of the weld overlay.
211- 2 LIMITATIONS
211- 1.3 Damaged Base Metal 211- 2.1 Additional Requirements
In carbon steel or low alloy steel applications, weld
overlay or weld buildup can be used to rebuild areas that Part 1 of this Standard, “Scope, Organization, and Intent,"
are worn from erosion, corrosion, or flow-accelerated contains additional requirements and limitations. This
corrosion (FAC), or which have been ground out to remove Article shall be used in conjunction with Part 1.
defects such as cracks. The original pressure boundary
integrity of the base metal can be restored.
211- 2.2 Base Metal Condition
This Article shall apply to wall thinning and does not
211- 1.4 Damaged Weld Overlay and Cladding specifically address other types of surface defects. See
Corrosion resistant weld overlay can be used to replace Article 304, "Flaw Excavation and Weld Repair" for other
damaged areas that originally had similar overlay, or that types of surface defects. The remaining base metal
originally had corrosion resistant cladding over carbon thickness shall be adequate to accommodate weld buildup.
steel or low alloy steel material. Corrosion resistant weld
overlay can also be used to back-clad seams that have been 211- 3 DESIGN
repaired on clad material with carbon steel or low alloy
steel base metal. 211- 3.1 Cause of Damage
211- 1.5 Definitions Prior to repair welding, determination should be made of
the causes of the damage to the weld overlay, cladding, or
211-1.5.1 Weld Overlay. For the purpose of this
base metal. The use of weld overlay or weld buildup as a
Article, weld overlay refers to the application of corrosion
permanent repair should include consideration of the
resistant weld metal on carbon steel or low alloy base metal.
thinning mechanism and its prevention. Consideration
211-1.5.2 Weld Buildup. Weld buildup refers should be given to replacement of all or part of the weld
specifically to the application of carbon steel or low alloy overlay in case there is damage to the cladding or weld
weld metal, applied for the purpose of restoring base metal overlay (corrosion, embrittlement and cracking, etc.).
thickness.
211-1.5.3 Clad Restoration. Clad restoration refers
to the application of corrosion resistant weld metal on
carbon steel or low alloy base metal, for the purpose of
restoring the original corrosion resistant weld

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 ASME PCC-2-2018

211- 3.2 Number of Weld Layers 211-3.8.2 Galvanic Corrosion. The possibility of
Weld overlay or back cladding may be deposited in galvanic corrosion should be considered in the base metal
one or more layers. More than one layer is required at the edge of high alloy or nonferrous weld overlay.
where temper-bead techniques are used. The number of
weld layers in production shall not be less than the 211-4 FABRICATION
number of layers deposited for weld overlay procedure 211-4.1 Surface Preparation
qualification tests.
Surfaces to be welded shall be free of rust, scale, paint,
211- 3.3 Weld Thickness coatings, and other contaminants, and shall have a smooth
The total depth of overlay or back cladding shall be 3 contour. If surfaces are to be prepared by blasting, media
mm (1/8 in.) or greater in thickness, unless otherwise should be free of silica that would interfere with subsequent
specified. In all cases, the weld overlay thickness and the welding operations.
base metal thickness shall at least equal the minimum
thickness of the undamaged metal. 211-4.2 Welding Procedure Qualification
Welding procedures, welders, and welding operators
211- 3.4 Multiple-Layer Welding
shall be qualified in accordance with the current
If multiple-layer overlay or back cladding is required requirements of the applicable construction code or
to meet the specified chemistry, and subsequent postconstruction code. If not otherwise specified, ASME
machining or grinding is necessary to satisfy BPVC, Section IX may be used for procedure and
dimensional requirements, the final machined or ground performance qualifications. Typically, semiautomatic
overlay thickness shall not be less than the qualified welding processes such as GMAW are used to maximize
thickness. Examples include machining of gasket productivity and to minimize heat input For larger areas to
grooves in flanges and tube- sheets or grinding of heat be welded, machine approaches using welding equipment
exchanger shell inside diameter to permit insertion of mounted on tracks for better control and productivity rates
tube bundle. may be appropriate.
211- 3.5 Base Metal Restoration
211-4.3 Weld Overlay
When the strength of the original base metal is to be
restored by weld buildup, the weld metal tensile 211-4.3.1 Heat Input. Application of the first overlay
strength should equal or exceed that of the base metal. pass in thin shells shall be such that penetration, and thus
Consideration should also be given to compatibility of the potential for burn-through, is minimized. In general,
the weld metal with the base metal and suitability for the heat input shall be minimized to prevent burn-through and
intended service. distortion.
211- 3.6 Corrosion Protection 211- 4.3.2 Weld Overlay Thickness. Weld overlay
thickness shall be verified by actual measurement of the
Where weld overlay is applied for corrosion
exposed edge at weld joint preparations or repair cavities.
protection, such as stainless steel overlay on carbon
Questions regarding overlay thickness should be resolved
steel or low alloy base metal, appropriate weld
by thickness measurements. Consultation with an NDE
chemistry (such as Type 309 followed by Type 308 filler
specialist may be necessary.
metal) should be specified.
211- 3.7 Design Calculations 211-4.4 Back Cladding
All design calculations should be in accordance with 211-4.4.1 Weld Groove Preparation. (Typical weld
the original construction code. If overlay or cladding is joint details for back cladding are shown in Figure
included in the thickness calculations, the calculations 211- 4.4.1-1.)
shall be in accordance with the original construction Prior to back cladding butt joints, the weld groove in the
code or, when none exists, they may be based on ASME backing material shall be filled approximately flush with,
BPVC, Section VIII, Division 1, UCL-23. but not more than 1.5 mm (1/16 in.) below the weld overlay
fusion line or the clad bond line adjacent to the weld groove
211- 3.8 Other Considerations
prior to back cladding. Care shall be taken to avoid cross-
211- 3.8.1 Differential Thermal Expansion. contaminating the cladding and backing material weld
Consideration should be given to differential thermal metal. Any suspected areas of cross-contamination shall be
expansion between the base metal and weld overlay. etched with either a nitric acid or copper sulfate solution to
confirm the location of the clad/ substrate interface.

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 ASME PCC-2-2018

211-4.4.2 Strip Back. Prior to back cladding butt joints, reduce the risk of cracking in embrittled base metals
cladding shall be stripped back a minimum of 6 mm (1/4 in.) during welding repairs.
from the edge of the plate, pipe, or fitting. 211-4.5.3 Intermediate PWHT. After performing weld
repairs to low alloy steel base metal, but before application
211- 4.5 Special Considerations for Low Alloy of weld overlay (if applicable), a dehydrogenation heat
Steels treatment or an intermediate PWHT should be considered,
211-4.5.1 Dehydrogenation Heat T reatment. Prior to any repairs especially if the base metal is 21/4Cr or higher alloy, or
being performed, consideration should be given to the need heavy wall (greater than 38 mm or 11/2 in. thick).
for a dehydrogenation heat treatment of vessels or parts
211- 4.5.4 Hardness and Toughness. Consideration
that have been exposed to products or processes containing
should be given to the maximum hardness and toughness
hydrogen to avoid hydrogen cracking during repairs.
needed in weld metal and in base metal heat-affected zones
Dehydrogenation heat treatment may be performed as
for the intended service.
outlined within API RP 934.
211-4.5.2 Embrittlement. Some materials may have 211- 4.6 Surface Profile
been exposed to service conditions that cause Finished surfaces should be free of undercut, notches,
embrittlement of these materials. Consideration should be sharp ridges, and abrupt surface changes. Grinding may be
given to the prior service conditions and the potential required to eliminate irregularities or pits.
damage in materials resulting from these service
conditions. This may require special welding procedures
and techniques to minimize the risk of cracking during
welded repairs. For example, the use of welding procedures
that provide controlled deposition and low welding heat
input

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 ASME PCC-2-2018

211-4.7 Heat Treatment 211-5.2 Copper Sulfate Solution Testing

211-4.7.1 General. Heat treatment shall be performed After removal of any damaged stainless-steel weld
in accordance with the applicable construction code or overlay, and prior to applying new weld metal, carbon steel
post-construction code, or owner-user specification. As an surfaces should be examined with copper sulfate solution to
alternative to heat treatment, and if allowed by the verify complete removal of stainless steel. (See ASTM A380
applicable construction code or post-construction code and for copper sulfate testing.)
approved by the owner, consideration may be given to the
211-5.3 Liquid Penetrant Examination of Weld
use of alternatives such as temper bead welding
procedures.
Overlay and Back Cladding
211-4.7.2 Prior PWHT. Consideration should be 211-5.3.1 Multiple-Layer Welds. For multiple-layer
given to the effect of any prior postweld heat treatments weld overlay or back cladding, liquid penetrant
(PWHT) and any additional PWHT for welded repairs on examination should be performed on the first layer of the
cladding and on strength and toughness of the base metal weld overlay.
and welded joints.
211-5.3.2 Finished Surfaces. The final surface of
211-4.7.3 Low Alloy Steels. In case of repairs to the weld overlays, back cladding, and welds joining
cladding or weld overlay on low alloy steels (e.g., Cr- Mo), attachments to weld overlays or integral cladding should be
the repaired area may be subjected to final PWHT any time liquid penetrant examined to an appropriate extent.
after the deposition of 5 mm (3/16 in.) of the first layer of the
corrosion resistant weld deposit (unless another depth is 211-5.3.3 Examination and Acceptance
qualified). Final PWHT may be performed either before or Standards.
after the deposition of additional layers of overlay since Examination and acceptance standards shall be in
only the first layer of weld deposit will cause a HAZ in the accordance with the applicable construction code or
base metal. Subsequent layers of welding would not be postconstruction code. If no standard is specified by the
expected to create a new HAZ in the base metal. applicable construction code or post-construction code, the
examination may be conducted in accordance with ASME
211-5 EXAMINATION BPVC, Section V, and acceptance criteria may be in
accordance with ASME BPVC, Section VIII, Division 1,
211-5.1 General Mandatory Appendix 8. Defective areas shall be repaired
211-5.1.1 Nondestructive Examination Before and reexamined.
Welding. Consideration should be given to the need for
nondestructive examination of surfaces to be welded. An 211-6 TESTING
appropriate method such as magnetic particle or liquid 211-6.1 Chemical Analysis
penetrant may be utilized to ensure that all defects have
211-6.1.1 Procedure Qualification. The chemical
been removed before the welding. Any unacceptable
indications that are discovered shall be removed in composition at the "effective depth" of the overlay or back
accordance with Article 304, "Flaw Excavation and Weld cladding should be included in welding procedure
Repair,” of this Standard prior to application of weld qualification tests.
overlay. The acceptance criteria shall be in accordance with 211-6.1.2 Production Welding. Alternatively, the
the applicable construction code or post-construction code. chemical composition at the “effective depth" of the overlay
211-5.1.2 Nondestructive Examination After or back cladding shall be reported for production welding,
Welding. when specified by the owner. The acceptance criteria for
Consideration should be given to the need for production overlay and back cladding shall be in
nondestructive examination of surfaces repaired by accordance with the owner’s specification except as noted
welding. Surface examination methods such as magnetic in this Standard.
particle, liquid penetrant, ultrasonic, or surface eddy 211-6.1.3 Extent of Chemistry and Ferrite
current may be utilized in accordance with the applicable Testing
construction code or post-construction code. Welds on base
(a) The number of samples for chemical analysis for all
metal over 9.5 mm (3/8 in.) thick should be examined by
types of weld overlay and back cladding, and number of
volumetric examination methods such as radiographic or
ferrite measurements for austenitic stainless-steel deposits
ultrasonic testing. The acceptance criteria shall be in shall be as specified by the owner. When required, test
accordance with the applicable construction code or post- samples should be removed, or in situ tests should be
construction code. conducted, prior to final PWHT (if applicable] at locations
selected by the field inspector. Testing after PWHT is not
required unless otherwise specified by the owner.

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(1) For machine weld overlay, one sample or test instrument calibration should be verified on at least two
from each girth weld and component (such as head, tube- standards (calibration test blocks) with a minimum ferrite
sheet, connection, etc.), and each back-clad seam is spread of 5 FN. At least one of these standards should have
recommended. For manual weld overlay, two samples or a FN of 4 to 10.
tests from each girth weld and equipment component (such (a) These standards should be one of the following:
as head, tube sheet, connection, etc.), and each back-clad (1) primary or secondary weld metal standards
seam are recommended. described in AWS A4.2/A4.2M
(2) For back-clad seams  600 mm (24 in.) in (2) samples with certified chemical analyses
diameter, one sample for each 24 diametral-inch, or part referenced to the WRC-1992 (FN) Diagram or the DeLong
thereof, is recommended. The 24 diametral-inch (FN) Diagram
measurement is cumulative for all back-clad seams 600 mm (3) samples with ferrite content measured by metal-
(24 in.) diameter and smaller employing the same welding lographic techniques
procedure, process, and filler metal. 211-6.5 Ferricyanide Testing of Ni-Cu (Alloy
EXAMPLE: One 20 in. manway and three 8 in. nozzles ~ 44 400) and Cu-Ni Alloys
diametral-inches; or one 500 mm manway and three 200 mm
(a) Ferricyanide testing should be performed on all
nozzles ~ 1 100 mm diameter measurement. Therefore, two tests
nickel-copper [Alloy 400 (Monel), 67Ni-30Cu) and copper-
are required.
nickel (70Cu-30Ni, 90Cu-10Ni) alloy overlays and back
(b) For repetitive manual, semi-automatic, and cladding.
automatic weld overlay operations on components > 600 (b) Ferricyanide tests should be performed on 100% of
mm (24 in.) diameter, two tests per welder per week may finished nickel-copper or copper-nickel overlays and back
be substituted for the requirements of (a)(1) above. cladding deposits. The results should not indicate the
However, there shall be no change in welding procedure, presence of free iron.
filler metal classification, batch number of submerged arc The suggested test procedure is as follows:
or electroslag flux, or welding position. Authorization shall (1) The surface to be examined should be prepared by
be at the discretion of the owner. a method that does not cause contamination by free iron. A
211-6.2 Chemical Composition of Austenitic solvent or detergent solution should remove oil, grease, and
dirt. A pickling solution may be used to remove oxides. The
Stainless Steel Weld Deposits surface should be thoroughly rinsed after pickling or
The chemical analysis shall be within the range specified detergent cleaning, using distilled or de-ionized water. If
in the original construction code, or in ASME BPVC, Section mechanical surface preparation is required, new emery
II, Part C. paper or grinding wheels, and nonferritic buffing wheels
and brushes should be used.
211-6.3 Ferrite Testing of Austenitic Stainless
(2) Suggested composition of the test solution is as
Steel Weld Deposits follows:
Suggested requirements for austenitic stainless-steel (-a) 90% by volume potassium ferricyanide (4%
ferrite numbers are as follows: solution)
(a) The ferrite content of the deposited weld overlay or (-b) 10% by volume solution consisting of 1 part
back cladding at the effective depth (as defined in section concentrated hydrochloric acid (36% to 38% by weight
211-1) should be as follows: HC1) and 9 parts distilled water
(1) For Type 304, 304L, 316,316L, and 317L, the FN (3) Fresh test solution should be prepared
range should be 4 to 10. immediately before application.
(2) For Type 347, the FN range should be 3 to 10. (4) The testing solution's reaction should be checked
(b) The ferrite content should be determined by one of on samples of nickel-copper or copper-nickel and carbon
the following: steel. A blue color should appear immediately on carbon
(1) The actual, as-deposited chemical composition steel. No color should appear on nickel-copper or copper-
and the WRC-1992 Constitution Diagram nickel within 10 min. If color does appear, the solution is too
(2) Magnetic instrument as listed in AWS A4.2/ acidic, and new solution should be formulated.
A4.2M. (5) Solution should be applied to the tested surface by
spraying (using an atomizer) or drop-by-drop (using an
211-6.4 Calibration of Magnetic Ferrite Testing eyedropper). Appearance of a definite blue color within 2
Gages min indicates the presence of free iron. A light blue tint
Magnetic gages should be calibrated and certified per AWS should be considered insignificant
A4.2/A4.2M. An annual calibration certification should be
available to the inspector. Prior to use in production,

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 ASME PCC-2-2018

(1) Questions regarding determination of iron ASME Boiler and Pressure Vessel Code, 2007 Edition,
content based on the degree of blueness should be Section V — Nondestructive Examination
resolved by spot chemical analysis. The iron content ASME Boiler and Pressure Vessel Code, 2007 Edition,
should not exceed 6%. Section VIII, Division 1 — Rules for Construction of
Pressure Vessels
211-6.6 Hydrostatic Testing
ASME Boiler and Pressure Vessel Code, 2007 Edition,
The inspector should be consulted to establish the
need for hydrostatic testing of equipment after repairs Section IX — Welding and Brazing Qualifications
are complete. Pressure testing is generally not needed Publisher: The American Society of Mechanical Engineers
for weld buildup and restoration type repairs, but if (ASME), Two Park Avenue, New York, NY 10016-5990
specified, should be in accordance with the (www.asme.org)
construction code or post-construction code.
ASTM A380, Standard Practice for Cleaning, Descaling, and
(18) 211-7 REFERENCES Passivation of Stainless Steel Parts, Equipment, and
The following is a list of publications referenced in Systems
this Article. Unless otherwise specified, the latest Publisher: American Society for Testing and Materials
edition shall apply. (ASTM International], 100 Barr Harbor Drive, P.O. Box
C700, West Conshohocken, PA 19428-2959
ANSI/NB-23-2007, National Board Inspection Code [www.astm.org]
Publisher: American National Standards Institute
(ANSI), 25 West 43rd Street, New York, NY 10036 AWS A4.2/A4.2M:2006 ISO 8249:2000], Standard Practice
(www.ansi.org) for Calibrating Magnetic Instruments to Measure the
Delta Ferritic Content of Austenitic and Duplex Ferritic-
API RP 582, Welding Guidelines for the Chemical, Oil Austenitic Stainless Steel Weld Metal
and Gas Industries Publisher: American Welding Society (AWS), 8669 NW 36
API RP 934, Materials and Fabrication Requirements Street, No. 130, Miami, FL 33166 [www.aws.org]
for 21/4Cr-lMo and 3Cr-lMo Steel Heavy Wall
Pressure Vessels for High Temperature, High Repairs of Deaerators
Pressure Hydrogen Service Publisher: Electric Power Research Institute (EPRI), 3420
Publisher: American Petroleum Institute (API], 1220 Hillview Avenue, Palo Alto, CA 94304 [www.epri.com]
L Street, NW, Washington, DC 20005
Baker, K., Jr. R. Sloan, J. R. Sloan, and E Upitis. Repair of a
(www.api.org]
21/4Cr-lMo Petrochemical Reactor WRC Bulletin 412:95-
ASME Boiler and Pressure Vessel Code, 2007 Edition, 105
Section II, Part C — Specifications for Welding Rods, WRC-1992,Constitution Diagram for Stainless Steel Weld
Electrodes, and Filler Metals Metals; Kotecki, D.J. and Siewert, TA

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 ASME PCC-2-2018

Article 212
Fillet Welded Patches

212- 1 DESCRIPTION (c) This repair method shall not be used where the
(a) This repair method describes the selection criteria,
damage mechanism, the extent of damage, or likely future
application limitations, design, fabrication, examination, damage cannot be characterized. This repair method may
and testing of fillet welded surface patches to pressure- be used in certain cases on areas with local crack-like flaws,
retaining components. Similar fillet welded surface patch provided
(1) the growth has stopped, been arrested, or can be
repair methods with reinforcing plug welds are provided in
Article 207. accurately predicted for all propagation modes
(2) the effect of the flaw is evaluated using detailed
(b) This repair method consists of fitting a repair plate
to closely match the original component’s exterior or analyses
interior surface. The repair plate is sized to cover the areas 211- 3 DESIGN
exhibiting damage, both at the time of repair and that
anticipated for the repair’s design life. 212- 3.1 General
(c) The repair method is typically applied to pressure-
(a) The design approach for this repair method is based
retaining shells that have suffered local wall thinning
in part on standard pressure component design
(including through-wall) due to erosion, corrosion, and
calculations, such as those in the ASME BPVC, Section VIII,
other local damage mechanisms.
Division 1. The application limitations imposed in section
(d) This repair method is applicable to cylindrical,
212-2 apply to the governing load case resulting from
spherical, flat, and conical shells as well as other pressure
internal pressure where the resultant stress is membrane
components.
stress. However, if the component to be repaired is subject
(e) This repair method is generally suitable for service
to bending, torsion, wind loads, or to fatigue, the design
temperatures above the nil-ductility temperature of the
shall include evaluation of these conditions using
materials of construction up to a maximum design
appropriate methods of analysis. In all cases, an engineering
temperature of 345°C (650°F). Use of this repair method for
analysis shall be performed.
lower temperatures requires evaluation of notch
(b) In general, the patch material and welding filler
toughness, nonductile fracture and other applicable low
metal should be the same or very similar (e.g.,
temperature effects. Use of this repair method for higher
compositional, physical, and mechanical properties) to that
temperatures requires evaluation of thermal fatigue, creep,
of the pressure component’s original construction. Repair
and other applicable high temperature effects.
material selection shall consider, as a minimum,
(f) Figure 212-1-1 shows a typical application on a
characteristics such as chemistry, weldability, physical
vessel with a nearby structural discontinuity (in this case a
properties (such as coefficient of thermal expansion),
nozzle). The plan view on top shows two of many possible
mechanical properties (such as strength, ductility, notch
repair patch configurations, which are generally rectilinear
toughness), and compatibility with the process medium.
in shape with rounded corners. The bottom sectional view
(c) The thickness of the patch plate is dependent on
shows the curvature matching aspect of each repair plate.
material mechanical properties and the calculated
212- 2 LIMITATIONS attachment weld sizes.
(d) The size (length and width) of the patch plate is
(a) Part 1 of this Standard, "Scope, Organization, and governed by the requirement that all attachment welds be
Intent," contains additional requirements and limitations. located on sound base metal completely encompassing the
This Article shall be used in conjunction with Part 1. damaged area(s) (see Figure 212-1-1). The repair plate
(b) This repair method is not limited by the component shall also be large enough to encompass any additional
size. However, a sleeve type repair may be more suitable for area(s) anticipated to experience similar or related damage
those applications where axisymmetric behavior is during the life of the repair. The patch plate should overlap
important sound base metal by at least 25 mm (1 in.).

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ASME PCC-2-2018

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 ASME PCC-2-2018

(a) This repair method is generally used on the

outside surface of components subject to internal
pressure. For applications under external pressure, a (2) Longitudinal Load. Unit forces in longitudinal
separate analysis to evaluate buckling and other direction:
instability considerations shall be performed.
(b) In assessing the applicability and service life of
this repair method, consideration shall be given to
material compatibility, future operating conditions,
thermal and shrinkage effects of welding, the
introduction of crevices and structural discontinuities,
thermal transients and temperature differentials
between the patch plate and the component, and other
application limits such as examination and testing
constraints. If the damage to be patched is, or is
expected to be, through-wall, the effects of fluids (e.g.,
entrapment, concentration, corrosion, etc.) that may
accumulate between the vessel and the patch plate
shall be assessed. If this repair method is to be
implemented during component operation, additional
precautions may need to be taken for personnel
safety.
(c) The design may consider the combined
strength of the patch plate (considering also the
strength of the fillet weld joints, including joint
efficiency] and the underlying shell. Consideration
may also be given to excess thickness available
adjacent to the damaged shell using applicable code
area replacement rules for nozzles. No credit shall be
taken for material required for future corrosion
allowance. where
F lp = longitudinal force due to internal pressure, N/ mm
(18) 212-3.2 Internal Pressure Loads (lb/in.)
(a) For cylindrical components subject to internal (b) If other loads are applicable (such as bending,
pressure loads, applied forces on the repair patch torsion, wind, etc.), they shall be determined and added to
shall be determined as follows: the pressure load such that
(1) Circumferential Load. Unit forces in Fc = Fcp + Fco
hoop direction:
and
F l = F LP + FLO
where
F c = total circumferential force from all loads, N/mm
(lb/in.)
Fco = circumferential force due to other applicable
loads, N/mm (lb/in.)
F l = totallongitudinalforcefromallloads,N/mm(lb/ in.)
F lo = longitudinal force due to other applicable loads,
N/mm (lb/in.)

(c) Appropriate alternative force calculations for

spherical, torispherical, or ellipsoidal pressure components
shall be used when applicable.
where
212- 3.3 Structural Discontinuity Evaluation
D m = diameter at mid-wall of component, mm (in.) (a) For stresses near a nozzle or other structural
F cp = circumferential force due to internal discontinuity to be insignificant, the minimum distance
pressure, N/mm (lb/in.) between the fillet welded patch plate and the existing
discontinuity should be

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 ASME PCC-2-2018

Lmin =2 (Rmt)1/2 (3) (a) Alternatively, the perimeter weld edge preparation
may be beveled to increase the weld's effective throat
where
thickness. In no case shall the effective throat exceed
Lmin = plate setback distance [see Figure 212-1-1),
mm [in.) the nominal thickness of the repair plate or the original
R m = radius at mid-wall of component, mm [in.) nominal component thickness.
(b) In addition, load path eccentricity of the hoop stress
t = wall thickness of component, mm [in.) in the shell plate and patch plate shall be considered. The
perimeter welds bearing circumferential loads shall be
Equation (3) applies the setback distance (Rmt)1/2 to
both the existing nozzle [or other similar structural
discontinuity) and the patch plate.
This proximity limit also applies to the distance
between adjacent fillet welded patch plates, in those
applications where more than one is employed on a
given component
(b) In those applications where the patch plate is to
attach to existing nozzle reinforcement pads, the patch
plate may be contoured to match the reinforcement
pad perimeter and welded thereto with a full
penetration joint.
(c) In those applications where the
damaged shell is within Lmin of a nozzle or other
structural discontinuity, the patch plate should be where
designed as a reinforcement pad extending 360 deg e = load path eccentricity (T + t)/2, mm (in.)
around the nozzle/opening, and welded thereto with a SW = calculated weld stress, MPa [psi); S w  1.55
full penetration joint. Alternatively, additional detailed T = wall thickness of patch plate, mm (in.)
analysis may be performed to evaluate local stresses.
212- 3.5 Cold Forming Limits
(18) 212-3.4 Allowable Load on Perimeter Fillet Weld
(a) The perimeter weld shall be sized such that the 212-Carbon and low alloy steel patch plates fabricated by
allowable load on the weld exceeds the longitudinal cold forming shall not exceed 5% extreme fiber elongation.
and circumferential loads in accordance with eq. (4). The extreme fiber elongation shall be determined as
follows:

213- For double curvature

where
Rf = final centerline radius of patch plate, mm (in.)

Ro = original centerline radius of patch plate (equals

infinity for flat plate), mm (in.)
where
E = weld joint efficiency factor [0.55) T = thickness of the patch plate, mm (in.)
F A = allowable force on fillet welds, N/mm (lb/in.); F a
> F c and F L
S a = allowable base metal stress, MPa (psi)1
wmin = minimum weld leg dimension, mm (in.)

NOTE: The maximum design fillet weld size shall not (a) Patches cold formed beyond these limits may be
exceed the thickness of the thinner material being used provided they receive appropriate post forming stress
joined nor 40 mm (1.5 in.). relief prior to installation.
(b) 4 FABRICATION
1 Compatible weld metal shall be of equal or greater Plate edges may be cut to shape and size by mechanical
strength. means such as machining, shearing, grinding, or by thermal
means such as flame or arc cutting. If

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 ASME PCC-2-2018

means are used, a minimum of 1.5 mm ( 1 / 1 6 in.) additional

material shall be removed by grinding or machining. If the
repair plate is greater than 25 mm (1 in.) thick, and the fillet 212- 5 EXAMINATION
weld size is less than the plate thickness, the weld prep (a) Patch plate attachment welds shall be
edges shall be examined by magnetic particle (MT) or liquid examined in accordance with the applicable
penetrant (PT) methods to check for laminations. construction code or postconstruction code by either
Laminations shall be cause for rejection unless repaired or the MT or PT methods if not temperature limited by
found acceptable by fitness-for-service analysis in the test methods. If not otherwise specified by the
accordance with API 579-1/ASME FFS-1. applicable construction code or postconstruction
(a) The patch plate may be formed to the required shape code, NDE shall be performed using procedures
by any process that will not unduly impair the mechanical written and qualified in accordance with ASME BPVC,
properties of the patch plate material. Where required due Section V.
to repair plate size or access/inter- ference considerations, (b) If lifting lugs are used and left in place, their
split sections may be used when joined by full penetration attachment welds shall be examined by MT or PT
welds. methods. At all locations where temporary lifting lugs,
(b) Parts to be fillet welded shall be fit as tightly as welded clamps, and/or wedges are removed after
practical to the surface to be welded and in no event shall be patch plate installation, the removal areas shall be
separated by more than 5 mm (3/16 in.). If the separation at examined by MT or PT methods.
the faying edge of the plate is 1.5 mm (1/16 in.) or greater, (c) Welds joining sections of patch plates made of
the size of the perimeter weld shall be recalculated by separate pieces should be surface contoured and
adding the amount of the separation to the eccentricity, e. volumetri- cally examined by either radiographic or
(c) Welding procedures, welders, and welding operators ultrasonic examination methods to the extent
shall be qualified in accordance with the current possible. If not practicable, multilayer PT or MT
requirements of the applicable construction code or examinations should be performed.
postconstruction code. If not otherwise specified, ASME BPV (d) If postweld heat treatment is required, the
Code, Section IX may be used for procedure and examination shall be performed after application of
performance qualification. Article 210 should be consulted PWHT.
for in-service welding issues; Article 214 should be (e) The examination acceptance criteria of the
consulted for field heat treating issues. applicable construction code or post-construction
(d) Field repair activities should conform to the code shall apply.
following sequence:
(1) Paint, scale, rust, liquids and other foreign material
212- 6 TESTING
shall be removed from the weld zone and an area not less (a) Testing shall be performed in accordance with
than 40 mm (11/2 in.) on either side of the weldment the applicable post-construction code.
(2) In those areas that will be covered by the new (b) The pressure component and installed patch
patch plate, existing shell seam or girth welds should be plate(s) should be leak tested in accordance with the
ground flush with the vessel or pipe O.D. and should be applicable post-construction code. Special safety
examined by the MT or PT method. precautions should be taken when pneumatic leak
(3) The new patch plate may be placed in position testing is performed.
using any suitable method. (c) If permitted by the applicable post-
(4) Any seams within the patch itself should be made construction code, nondestructive examination may
first. The perimeter weld may then be completed. Clamps or be performed as an alternative to leak testing. Also, an
wedges may be used to ensure proper joint alignment and initial service inspection may be performed of all weld
fit-up. joints after the pressure component has returned to
(e) Exposed metal surfaces should be recoated, if normal operating pressure and temperature, if these
applicable, after completion of all examination and testing. were reduced while welding was performed.
(f) To preclude gas pressure buildup between the patch (d) Testing and inspections should be performed
plate and the pressure component boundary, provisions for prior to reapplication of coating, insulation, or
venting during the final closure weld or, if applicable, post jacketing, as applicable.
weld heat treatment, may be necessary. If the patch plate is
designed for through-wall defects but applied to the 212-7 REFERENCES (18)
pressure boundary before being breached, the vent should The following is a list of publications referenced in
be sealed after completion of welding and, if applicable, post this Article. Unless otherwise specified, the latest
weld heat treatment. edition shall apply.

API 579-1/ASME FFS-1, Fitness-for-Service, June 5, 2007

Publisher: American Petroleum Institute (API), 1220 L
Street, NW, Washington, DC 20005 (www.api.org)

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 ASME PCC-2-2018

ASME Boiler and Pressure Vessel Code, Section V — ASME Boiler and Pressure Vessel Code, Section IX —
Nondestructive Examination ASME Boiler and Pressure Welding, Brazing, and Fusing Qualifications Publisher: The
Vessel Code, Section VIII, Division 1 — Rules for American Society of Mechanical Engineers (ASME], Two
Construction of Pressure Vessels Park Avenue, New York, NY 10016-5990 (www.asme.org)

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 ASME PCC-2-2018

Article 215
(18) Repair Welding Considerations for Cr-Mo Steel Pressure Vessels

215-2 LIMITATIONS
215- 1 DESCRIPTION
Part 1 of this Standard contains additional
215-1.1 Scope requirements. This Article shall be used in conjunction with
Repair welding considerations in this Article are Part 1.
applicable to pressure vessels for refinery, petrochemical,
215-3 DESIGN
power generation, and other services where the
requirements of this Article apply. Table 215-1.1-1 provides 215-3.1 Feasibility Study of Repair Welding
guidance for the applicability of repair welding for Cr- Mo
(a) The materials listed in Table 215-1.2-1 may be
steel pressure vessels.
repair welded provided an investigation has been
215-1.2 Application performed to determine the cause of the damage to be
(a) This Article describes weld repair considerations for repaired and provided appropriate weld repair procedures
pressure vessels made from Cr-Mo steels. The purpose of are used.
this Article is to provide a high-level overview of (b) The following should be assessed prior to
deterioration mechanisms and the subsequent factors that performing repair welding:
need to be considered in developing a detailed repair, (1) the structural integrity of the pressure vessel
examination, and testing plan for the successful repair of Cr- (2) the feasibility of the repairs
Mo pressure vessels. (3) the suitability of the pressure vessel for the
(b) The Cr-Mo materials listed in Table 215-1.2-1 of this intended service after the repairs are completed
Article are susceptible to certain types of damage in The serviceability or fitness-for-service assessment
elevated-temperature service (e.g., see WRC Bulletins 488, should be based on API 579-1/ASME FFS-1, as shown in
489, and 490). Figure 215-3.1-1.
(c) The repair of creep-damaged Cr-Mo steels, creep-
enhanced ferritic steels, vanadium-modified steels, or 215-3.2 Consideration of In-Service Degradation
stainless steel cladding or weld overlay are not included in (a) In-service degradation (see Table 215-3.2-1 and
this Article. See Article 211 for information on weld overlay Figure 215-3.3-1) shall be considered before developing a
and clad restoration; creep will be covered in a separate repair welding procedure.
Article in a future edition of this Standard. (b) Typical considerations for in-service degradation for
(d) API RP 571 and API 579-1/ASME FFS-1 provide weld repair are shown in Table 215-3.2-2.
further information on temper embrittlement and other (c) Further information on in-service degradation is
aging effects on the fracture toughness of Cr-Mo steels. provided in API RP 571 and in WRC Bulletins 488, 489, and
215-1.3 Design Temperature 490.
The maximum design temperatures of Cr-Mo materials 215-3.3 Examples of Damage
are as listed in the applicable codes of construction.
Figure 215-3.3-1 shows examples of damage that can
215-1.4 Applicable Materials occur in Cr-Mo pressure vessels with or without stainless
Typical Cr-Mo materials and their ASME designations are steel cladding or weld overlay. The examples are typical of
indicated in Table 215-1.2-1; however, equivalent high-temperature, high-pressure (HTHP) pressure vessels
international standard materials may also be used. in refining service.

215-3.4 Development of Weld Repair

Procedures
(a) The selection of weld repair method should be based
on the reliability of the repaired area considering the future
operation period, as shown in Figure 215-3.4-1.

85
 ASME PCC-2-2018

(b) Sleeve repair and partial patch repair methods (see 215-4.4 Preheating and Post-Heating
Table 215-3.5-1) are normally applied temporarily and (a) To prevent hardening of welds and cold cracking,
are not recommended for periods beyond the next preheating, post-heating, and dehydrogenation heat
upcoming shutdown or outage without appropriate treatment (DHT) shall be mandatory unless paras. 215-4.5
nondestructive examination (NDE) and applicable fitness- through 215-4.7 stipulate otherwise.
for-service assessment (b) Typical preheating and welding Interpass
215-3.5 Repair Welding Methods Applicable to Cr- Mo tempera tures are indicated in Table 2154.4-1.
Vessels
Some applicable repair welding approaches and 215-4.5 De-Embrittlement Heat Treatment
alternatives to post weld heat treatment (PWHT) and the When the materials are severely embrittled, a de-
ASME PCC-2 Articles in which they are described are listed embrittlement heat treatment operation may be used to
in Table 215-3.5-1, along with some additional limitations recover toughness of material, as shown in Table
and considerations. 213- 4.5-1.

215-3.6 Welding and Preheat 215-4.6 Dehydrogenation Heat Treatment

The preheat temperature should be maintained until
When the actual aged condition of the component to be
PWHT or DHT is performed. When the materials are
repaired cannot be sufficiently evaluated for development
required to cool to ambient temperature after repair
of a repair welding procedure, a bead-on plate test should
welding, dehydrogenation heating shall be carried out at a
be used to verify the repair welding procedure.
minimum of 300°C (570°F) for a minimum of 1 h, or for a
NOTE: A bead-on plate test is a type of self-restraint weld
test used to evaluate the cracking sensitivity of the base duration to be agreed upon between the purchaser and
materials and arc welding consumables. Refer to Keyano fabricator, to prevent cold cracking.
etal. and Yamamoto et al. (see section 215-7).
215-4.7 Post weld Heat Treatment
(a) PWHT should be performed when required per
215-4 FABRICATION applicable construction codes or standards.
215-4.1 Weld Repair Procedures (b) Temper bead and other welding methods as detailed
in Article 209 may be applicable to some low- chrome steels
(a) Weld repair procedures may be developed as when corresponding WPSs or procedure qualification
indicated in Table 215-4.1-1. records (PQRs) are developed specifically for the welding
(b) The welding procedure specification (WPS) shall be repair considering welding position and welding
qualified in accordance with ASME BPVC, Section IX, as circumstances.
applicable, and/or the requirements imposed by the (c) Temper bead methods are usually not
applicable construction code. appropriate for 21/4 Cr-l Mo and higher-chrome materials
used for hydrogen service because of the high weld-metal
215-4.2 Preparation for Welding and heat-affected zone (HAZ) harnesses generated by the
(a) For shielded metal arc welding (SMAW), drying of welding process.
electrodes shall be carried out to minimize the potential for (d) In case of local PWHT, the PWHT procedure
hydrogen cracking. developed shall include the arrangement of thermocouples
(b) Welding bevel surfaces shall be clean, dry, and free and insulation to minimize the thermal stresses generated
of oil, paint, or other contaminants. during the PWHT operation. AWS D10.10 and WRC Bulletin
452 provide guidelines for developing a PWHT plan with
215-4.3 Welding Conditions specific band widths (soak band, heated band, and gradient
control band] to ensure that thermal gradients are not
(a) To prevent hardening of welds, weld beads less than
harmful.
50 mm (2 in.) in length should be avoided.
(b) Special precaution shall be taken to guard against 215-5 EXAMINATION
brittle fracture due to local thermal temperature gradients. (a) NDE, as indicated in Table 215-4.1-1, shall be
(c) For one-side repair welding of piping, back considered at each appropriate step of repair welding work.
shielding should be considered for 21/4Cr -1Mo and higher The appropriate NDE procedure(s] for the applicable repair
alloy steels. shall be selected to meet the requirements of the applicable
(d) The temper bead welding method may be construction code and to provide the level of examination
considered after evaluation in some cases for low alloy necessary for the repair.
welds when PWHT will not be carried out See para. 215-4.7.

86
 ASME PCC-2-2018

(b) NDE procedures shall be in accordance with ASME conditions and shall be no higher than the vessel
BPVC, Section V and applicable construction codes and operating pressure.
standards. (e) When a pressure test is to be carried out,
(c) NDE before repair welding of pressure boundary consideration shall be given to the pressure train that the
shall include the following: pressure vessel is located in, the possibility of isolation of
(1) The entire area of the pressure vessel that is to be components within that train, and the need for pressure
repair welded shall be examined by means of visual testing the entire train.
examination (VT) or other NDE methods as may be
applicable to ensure that the area is free of any defect 215-7 REFERENCES
harmful to the repair operation, which may include welding, The following is a list of publications referenced in this
PWHT, and pressure testing. Article. Unless otherwise specified, the latest edition shall
(2) The need for carrying out pressure testing after apply.
repairs as well as the pressure used in pressure testing shall API RP 571, 2011, Damage Mechanisms Affecting Fixed
be evaluated in consideration of service conditions.
Equipment in the Refining Industry API 579-1 /ASME FFS-
(d) NDE after weld repair and after pressure test shall
1 2007, Fitness-For-Service API RP 934-A, Materials and
include the following:
Fabrication of 21/4Cr-lMo, 21/4Cr-lMo-1/4V, 3Cr-Mo, and
(1) Complete NDE shall be performed in an area that
3Cr-lMo-1/4V Steel Heavy Wall Pressure Vessels for High-
is at least the maximum of either 2T, where T is the thickness
Temperature, High-Pressure Hydrogen Service API RP
of material, or 100 mm (4 in.) from the edge of the repair-
934-C, Materials and Fabrication of l1/4Cr-V?.Mo Steel
welded, preheated, or post weld heat-treated area, to
Heavy Wall Pressure Vessels for High-Pressure Hydrogen
ensure the area is free of defects.
(2) NDE of the area described in (1) shall also be
Service Operating at or Below 825°F (441°C) API RP 934-
performed after any pressure test is carried out E, Recommended Practice for Materials and Fabrication of
(e) Acoustic emission testing may also be an effective 11/4Cr-1/2 Mo Steel Pressure Vessels for Service Above
means of examination following completion of repairs. 825°F (440°C)
(f) Where possible, in-service NDE monitoring during API RP 941, Steels for Hydrogen Service at Elevated
operation is recommended for the repaired areas. Temperatures and Pressures in Petroleum Refineries
(g) In some instances, NDE may be used in lieu of and Petrochemical Plants
pressure testing for repairs. Refer to Article 502. API TR 934-D, Technical Report on the Materials and
(h) Follow-up NDE after the pressure vessel is returned Fabrication Issues of 11/4Cr-1/2 Mo and lCr-V2Mo Steel
to service shall be performed based on fitness-for-service Pressure Vessels
assessment requirements or applicable international Publisher: American Petroleum Institute (API), 1220 L
surveys industry (ISI) codes. Street, NW, Washington, DC 20005 (www.api.org)

215-6 PRESSURE TESTING ASME Boiler and Pressure Vessel Code, Section V,
Nondestructive Examination ASME Boiler and Pressure
(a) The requirement for the applicability of a pressure Vessel Code, Section IX, Welding, Brazing, and Fusing
test subsequent to weld repairs shall be evaluated. Qualifications ASME PCC-3, Inspection Planning Using
(b) If a pressure test is determined to be required after Risk-Based Methods
the repair welding of pressure-bearing parts is completed, Kayano, R„ Abe, M., and Hirai, Y., "Guidelines for Repair
the pressure vessel or vessel part should be pressure tested Welding of Pressure Equipment in Refineries and Chemical
in accordance with the requirements of the applicable Plants: Part 3 — Carbon Steel, High Tensile Steel and Cr-
construction code. If the applicable construction code has Mo Steel,” paper no. PVP2011-57079 from the Proceedings
no such pressure test requirements, Article 501 should be of the ASME 2011 Pressure Vessels and Piping Conference,
followed. July 2011 Tahara, T„ Antalffy, L. P„ Kayano, R., and
(c) The pressure test, when required, shall be Tsutomu, K., "Chronological Review of Manufacturing
performed at a temperature higher than the fracture Technologies and Considerations of Maintenance/
appearance transition temperature (FATT) and at or above Inspection for Heavy Wall Hydroprocessing Reactors,"
the minimum temperature specified by the applicable paper no. PVP2013-97227 from the Proceedings of the
construction code, to prevent brittle fracture during the ASME 2013 Pressure Vessels and Piping Conference, July
pressure test. 2013
(d) The toughness value of degraded materials shall be
evaluated based on accumulated material database or
samples obtained from vessel parts.

For pressure vessels that operate in hydrogen service and

are to be hydrotested, the hydrotest pressure shall be
evaluated in consideration of hydrogen service

87
 ASME PCC-2-2018

Yamamoto, E., Tahara, T., Matsushita, Y„ and Minami, F., BS EN ISO 17642-2:2005, Destructive test on welds in
"Guidelines for Repair Welding of Pressure Equipment in metallic materials — Cold cracking tests for weldments —
Refineries and Chemical Plants: Part 1 — General,” paper Arc welding processes, Part 2: Self-restraint tests
no. PVP2011-57809 from the Proceedings of the ASME Publisher: British Standards Institution, Inc. (BSI), 12950
2011 Pressure Vessels and Piping Conference, July 2011 World gate Drive, Suite 800, Herndon, VA 20170
Publisher: The American Society of Mechanical Engineers (www.bsigroup.com)
(ASME), Two Park Avenue, New York, NY 10016-5990
WRC Bulletin 452, Recommended Practices for Local
(www.asme.org)
Heating of Welds in Pressure Vessels WRC Bulletin 488,
Atkins, D., Thiessen, D., Nissley, N., and Adonyi, Y., Damage Mechanisms Affecting Fixed Equipment in the
"Welding Process Effects in Weldability Testing of Steels," Pulp and Paper Industry WRC Bulletin 489, Damage
Welding Journal, April 2002 AWS D10.10/D10.10M, Mechanisms Affecting Fixed Equipment in the Refining
Recommended Practices for Local Heating of Welds in Industry WRC Bulletin 490, Damage Mechanisms Affecting
Piping and Tubing Publisher: American Welding Society Fixed Equipment in the Fossil Electric Power Industry
(AWS), 8669 NW 36 Street, No. 130, Miami, FL 33166 Publisher: Welding Research Council (WRC), P.O. Box
(www.aws.org) 201547, Shaker Heights, OH 44122
(www.forengineers.org/welding-research-council)

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 ASME PCC-2-2018

Table 215-1.1-1 Guide for the Selection of Repair Technique

General
Local Wall Lamination Circumferential Longitudinal
Article Number and Title Wall Pitting Gouges Blisters
Thinning s Cracks Cracks
Thinning
Article 215 Repair Welding
Considerations for Cr-Mo Y Y Y Y R R Y Y
Steel Pressure Vessels

GENERAL NOTE:
Y = generally appropriate
R = may be used but requires special cautions

Table 215-1.2-1 Cr-Mo Steels Applicable to This Article

ASME Designation

Typical Materials Plates Forgings Vessel Piping Components

SA-182-F12
1 Cr-1/2 Mo SA-387-12, Cl. 1 and C1. 2 SA-335-P12
SA-336-F12

SA-182-F11
1 ¼ Cr-1/2 Mo SA-387-11, C1. 1 and C1. 2 SA-335-P11
SA-336-F11

SA-182-F22, Cl. 1 and Cl. 3

SA-387-22, Cl. 1 and Cl. 2
21/4 Cr-1Mo SA-336-F22, Cl. 1 and Cl. 3 SA-335-P22
SA-542-B, Cl. 4
SA-541-F22, Cl. 3

SA-182-F21
3Cr-1Mo SA-387-21, Cl. 1 and Cl. 2 SA-335-P21
SA-336-F21, Cl. 1 and Cl. 3

5Cr-1/2 Mo SA-387-5, Cl. 1 and Cl. 2 SA-182-F5 SA-335-P5

SA-182-F9
9Cr-1Mo SA-335-P9
SA-336-F9

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 ASME PCC-2-2018

Figure 215-3.1-1 Standard Steps in Repair Welding

90
 ASME PCC-2-2018

Table 215-3.2-1 Typical In-Service Degradation

Applicable Operating
Type of Damage Degradation Phenomena Typical Susceptible Materials
Conditions
Toughness degradation in base
metal and welds through the
1Cr-V2Mo
intergranular micro segregation of
Temper 1¼ Cr-0.5Mo
370°C-580°C impurity elements as measured by
embrittlement 2¼ Cr-1Mo
(700°F-1,080°F) the J factor for 21/4 Cr and higher
[Note (1)] 3Cr-1Mo
Cr base metals, and the X bar factor
5Cr-1Mo
for weld metals and for 1Cr and
1 ¼ Cr base and weld metals
Carbide precipitation and crack
Creep Over 454°C (850-F) and initiation in the coarse grain HAZ 1Cr-1/2 Mo
embrittlement with applied load of a localized stressed area such as 11/4 Cr-1/2 Mo
at a nozzle attachment weld
Low-Cr materials in high-
HTHP hydrogen Generation of methane bubbles,
Hydrogen attack hydrogen, partial-pressure
environment blisters, and cracks [Note (2)]
environment
1Cr-1/2 Mo
HTHP hydrogen environment Toughness degradation by
Hydrogen 11/4 Cr-1/2 Mo
and start-up and shutdown hydrogen
embrittlement 21/4 Cr-1Mo
conditions absorption
3Cr-1Mo
Large temperature gradients
Thermal fatigue during operation, and start- Fracture crack propagation All materials
up and shutdown conditions

GENERAL NOTE:
HAZ = heat-affected zone
HTHP = high temperature, high pressure

NOTES:
(1) Embrittlement manifests at lower temperatures during start-up and shutdown.
(2) See API RP 941.

Table 215-3.2-2 Typical Considerations for Weld Repair of In-Service Degradation

Type of Damage Main Concerns Repair Considerations [Note (1)]

De-embrittled heat treatment above 600°C (1,100°F),
Temper Low toughness at start-up and shutdown
then rapid cooling Use of welding materials with low
embrittlement Operating temperature limits Weldability
impurity levels

Elimination of stress riser, and higher-Cr material

Creep embrittlement Detection by NDE Flaw removal
selection

Higher-Cr material selection [Note [2)] Stainless steel

Hydrogen attack Detection by NDE Flaw removal
weld overlay cladding

Hydrogen Dehydrogenation heat treatment above 300°C (570°F),

Toughness at operating temp Weldability
embrittlement 1 h min. Low-hydrogen welding process

GENERAL NOTE:
NDE = nondestructive examination

NOTES:
(1) Table includes prevention/mitigation for repair and/or replacement
(2) Refer to API RP 941, Nelson chart.

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ASME PCC-2-2018

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 ASME PCC-2-2018

Table 215-3.5-1 Repair Methods Applicable to Cr-Mo Vessels

Types of Repair Relevant Article Additional Considerations

Replacement with Type B sleeve at the first

Sleeve repair Article 206
available opportunity is recommended
In case of corrosion metal loss, welding
Overlay welding and/or internal
Article 211 materials shall be selected considering cause
weld metal buildup
of corrosion
Thickness of insert plate shall generally not
Butt-welded insert plates Article 201
be thicker than shell or head

Alternatives to PWHT Article 209 Refer to para. 215-4.7

Alternatives to traditional welding

Article 208 ---
preheat

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 ASME PCC-2-2018

GENERAL NOTE:
FCAW = flux-cored arc welding
GTAW = gas tungsten arc welding
MT = magnetic particle testing
PQR = procedure qualification record
PT = penetrant testing
PWHT = post weld heat treatment
RT = radiography
SMAW = shielded metal arc welding
UT = ultrasonic testing
VT = visual examination
WPS = weld procedure specification

NOTES:
(1) Identify flaw size, distribution, location, and depth.
(2) Preheating is mandatory for Cr-Mo steels.
(3) See Article 208.
(4) See WRC Bulletin 452 for additional guidelines.

Table 215-4.4-1 Typical Preheat and Interpass Temperatures

Steel P-No./Group Minimum Preheating Maximum Interpass

Temperature, °C (°F) Temperature, °C (°F)
1Cr-1/2Mo, 11/4 Cr- 1/2 Mo 4-1 120 (250) 300 (600)

2 ¼ Cr-1Mo 5A-1 150 (300) 300 (600)

2 l/4 Cr-1Mo 5C-1 177 (350) 300 (600)

3Cr-1Mo 5A-1 150 (300) 300 (600)

5Cr-1/2Mo, 9Cr-1Mo 5B-1 200 (390) 300 (600)

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 ASME PCC-2-2018

Table 215-4.5-1 De-Embrittlement Heat Treatment

Type of Degradation Materials and Services to Be Considered De-Embrittlement

Not applicable due to irreversible

All Cr-Mo steels at HTHP hydrogen services
phenomena
1Cr-1/2 Mo, 11/4 Cr-1/2 Mo at over 480°C
Hydrogen attack Not applicable due to irreversible
(900°F)
Creep embrittlement phenomena
21/4+Cr-1Mo, 3Cr-1Mo at 370°C to 580°C
Temper embrittlement Heating at not less than 600°C (1,120°F)
(700°F to 1,080°F)
Hydrogen embrittlement Dehydrogenation shutdown operation or
21/4 Cr-1Mo, 3Cr-1Mo at high-temperature
heat treatment at not less than 300°C
hydrogen services
(570°F)

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 ASME PCC-2-2018

Article 216
Welded Hot Taps in Pressure Equipment or Pipelines

216- 1 DESCRIPTION (e) In selecting a suitable drilling machine to perform

(a) This Article provides requirements for design and the hot tap, consideration shall be given to
installation of fittings by welding on equipment while in (1) the system operating pressures and
service (in-service welding). temperatures during the performance of the hot tap
(b) This Article may be used in conjunction with (2) the wall thickness of the pipe, vessel, or tank to
owner/user requirements and with other relevant be cut through
documents pertaining to safe hot tapping practices. (3) the wall material of pipe, vessel, or tank
(c) This Article maybe used in conjunction with Article (4) the size of the hot tap to be made
210 on in-service welding. (5) the location of the hot tap and clearances
available
216- 1.1 Hot Tapping Connections (f) The drilling machine should be thoroughly
(a) Hot tapping is used to install a branch connection inspected before being operated to ensure that the critical
into piping, pipelines, pressure vessels or other pressure parts of the machine are not worn to the extent that they
equipment, and storage tanks while that equipment is in might fail during the hot tapping operation.
service. 216- 1.3 Hot Tapping Activities
(b) Hot tapping involves hot work, including welding on
the surface of a pressure vessel, pipe, or tank while in
216-1.3.1 Hot Tap Construction Activities.
Hot tap
service, and cutting through the pressure containment wall
design, fabrication, testing, and installation is a
material.
multidisciplinary activity. Hot tap personnel should be
(c) In-service hot tapping requires special
experienced and have knowledge of the construction codes,
considerations for
the activities involved during the execution of hot taps, and
(1) safety
recommended safe practices (e.g., API RP 2201, API RP
(2) planning with competent personnel and
2009).
appropriate procedures
(3) the type of fluids 216-1.3.2 Key Hot Tap Activities. The following lists
(4) pressure and temperature while in service some activities that are not specifically addressed in detail
(5) the use of proper equipment in this Article, but can be important in the successful
(6) testing execution of hot taps:
(7) examination (a) review of system details, including fluid
compositions, pressures, temperatures, and flow rates of
216- 1.2 Hot Tap Drilling Machine the system to be hot tapped. This includes normal operating
(a) The drilling machine generally consists of a conditions as well as specific conditions during the hot
mechanically driven telescoping boring bar that controls a tapping procedure.
cutting tool; the cutting tool consists of a hole saw [cutter), (b) preparation of hot tap mechanical design drawing
pilot drill, or both (see Figure 216-1.2-1). (s) and validation of the characteristics of the materials for
(b) The drill bit is used to bore a pilot hole into the long-term conditions and short term hot tap installation
vessel, pipe, or tank wall in order to center a hole saw that conditions.
cuts out the "coupon” or a curved section of the vessel or (c) process surveillance that ensures process operating
pipeline wall. variables, such as flow rates, are within the hot tapping
(c) The cutting tool or drill bit also incorporates a limitations while the hot tap operation is being executed.
device to "catch" the coupon and to ensure its removal from (d) review of prior and new ultrasonic thickness
the pipeline, vessel, or tank. measurements and defects in the area to be hot tapped.
(d) Small diameter taps sometimes employ a drill bit Hot tapping shall be approved by the owner prior to any
rather than a hole saw. field work on the pressure equipment and shall follow a
written procedure that is approved by the owner.

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ASME PCC-2-2018

216- 2 LIMITATIONS
216- 2.1 Additional Requirements
Part 1 of this Standard contains additional requirements
and limitations. This Article shall be used in conjunction
with Part 1.
216- 2.2 Nonwelded Fittings
This Article does not address fittings that are attached to
the vessel or piping while in service by methods other than
welding, such as bolted-on fittings or fiber-reinforced
polymer-filled fittings.
216- 2.3 Welding Concerns
For limitations associated with in-service welding, see
Article 210.
216- 2.4 Conditions and Applications for
Which Hot Tapping Is Not
Recommended
Hot tapping should not be used for the following
conditions and applications. The list below is not all
inclusive; there maybe additional applications for which hot
tapping poses unacceptable risks.
(a) vapor/air or vapor/oxygen mixtures within their
flammable explosive range
(b) oxygen or oxygen-enriched atmospheres
(c) temperature-sensitive, chemically reactive
materials
(d') Monel piping handling sulfur compounds
(e) stainless steel piping containing potassium
carbonate solutions
(f) pressure equipment that does not meet the impact
test requirements of the applicable construction code at the
operating temperature
(g) hydrogen service, unless an appropriate engineering
review has been performed to permit welding on such
equipment
(1) The metal temperature from the service
environment during the hot tap operation shall be below the
applicable curve in API RP 941, Fig. 1 to avoid hydrogen
damage at elevated temperature.
(2) Welding should not be done on carbon steel
equipment in-service containing hydrogen at operating
temperatures above 200°C (400°F).
(h) material requiring PWHT after hot tap welding and
where alternative welding methods are not acceptable

216-2.5 Conditions for Which Hot

Tapping Requires Special Precautions
Hot taps shall be performed under the following
conditions only if appropriate precautions are taken. The
precautions shall be specific to the condition and developed
with input from appropriate subject matter experts:

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 ASME PCC-2-2018

(a) on liquid-filled piping, vessels, or tanks with no flow. stresses on the pipe inner diameter. This approach
In such cases, the fluid system should be evaluated to should only be considered after a complete review of the
determine if a vent system is required to allow the egress of proposed hot tap is performed by an engineer
any vapors generated during the hot tapping process. knowledgeable and experienced in pressure vessel or
(b) on a vapor line that contains an explosive mixture. piping design, welding, and construction.
(c) on equipment operating in the creep range. (c) Controlled deposition techniques in lieu of PWHT,
(d) on equipment for which the operating pressure is such as described in Article 209, NB-23 Part 3, or in API 510
less than atmospheric. For equipment containing flammable or API 570, as applicable, and in ASME Section IX, QW- 290.
or combustible liquids and operating below atmospheric (d) For air-hardenable steels (e.g., 11/4 Cr-1/2Mo,
pressure, special requirements should be made to prevent 21/4Cr- 1Mo, 5Cr-1/2Mo), where PWHT is required by the
air from entering the process. Air leak into the process could applicable construction code or for service considerations,
create a flammable or combustible mixture. hot tapping may be performed if the metal temperature is
(e) on equipment subject to in-service conditions that maintained at or above the preheat temperatures listed in
can cause degradation of the equipment the applicable codes and standards. In such cases, the
NOTE: Stainless steel equipment that is susceptible to minimum preheat temperature should be maintained from
chloride stress corrosion cracking should be examined the time of the hot tap until the next shutdown, at which
prior to hot tapping to ensure that pre-existing cracking time PWHT of the connection should be performed prior to
is not present. recommissioning the line.
(f) on equipment subject to in-service conditions that
can produce carburization, nitriding, or other forms of 216- 2.7 Additional Requirements
embrittlement in the material to be welded. Such conditions
Hot taps should not be performed on vessels or piping
require that the welding procedure be evaluated with
that are subject to external pressure as a design
respect to process-side metal temperature to determine the
requirement unless consideration is given to the effects of
potential for embrittlement. The embrittled material should
distortion from fabrication, including welding, on the
be evaluated for weldability and suitability for continued
buckling strength of the vessel or pipe.
operation and the test condition.
(g) on pressure containments with concrete or
216- 3 DESIGN
refractory linings. In such cases, the potential for lining
detachment and subsequent flow blockage, hot spots, or 216- 3.1 Hot Tap Checklist
erosion should be evaluated. (a) The organization performing the hot tap should
(h) on compressed-air and other compressed-gas
prepare a checklist of all the considerations that need to be
systems.
evaluated and satisfied prior to the start of the hot tap.
(i) on piping fittings and valves.
(b) The checklist should include the considerations
(j) on vessels, piping, or tanks that are in sour service or
listed in API RP 2201, Appendix A, Table 1.
amine service, that transport or store caustics or acids, or
that are in use in other aggressive environments. 216- 3.2 Hot Tap Fittings
(k) on equipment for use with any hydrocarbons (e.g.,
ethylene, ethylene oxide, propylene oxide, acetonitrile 216- 3.2.1 Pressure Vessel and Tank Fittings. Hot
acetylene] that can experience exothermic decomposition tapping connections in pressure vessels and storage tanks
due to high temperatures caused by welding. typically are nozzles with or without reinforcing plates.
(l) on pipe or equipment that is clad, overlaid, lined, or
internally coated. 216- 3.2.2 Pressure Piping Fittings

216- 2.6 Additional Requirements (a) Connections to pressure piping may be of the
following types:
The need for PWHT should be evaluated on an individual
(1) pipe necks with or without reinforcing plates
basis. Consideration should be given to the following
(2) integrally reinforced branch outlet fittings as
alternative methods:
shown in MSS-SP-97
(a) For ferritic steel piping where PWHT is required for
(3) split tees designed for the specified design
hardness concerns, it is possible to demonstrate the
pressure at the specified design temperature
necessary hardness limit by mock-up. In such cases, hot taps
(b) The connections and attachment welds should also
maybe performed, provided the demonstrated test
be able to resist the loads and bending moments acting on
conditions and procedures are followed.
the pipe.
(b) For ferritic steel piping where PWHT is required for
residual stress concerns, it is possible to develop and
implement weld bead sequences that produce compressive

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(a) Consideration should be given to possible (d) The full encirclement sleeve shall be continuously
accelerated corrosion in split tees and full encirclement fillet welded at both ends of the run pipe. All weld sizes shall
reinforcement due to the gap between the split tee and pipe be adequate for the applied loads and shall be in accordance
wall. with the applicable construction code (see para. 206-3.5).
(e) Longitudinal welds that will be covered by a full
216- 3.3 Branch Design Requirements encirclement sleeve or reinforcing pad shall be ground flush
(a) Hot taps installed in pressure vessels, storage tanks, for the full length of the hot tap fitting plus 3 in. (75 mm) on
or piping systems shall meet the requirements (including either side of the sleeve or the pad plate.
nozzle reinforcement requirements) of the original
construction code or the applicable post-construction code, 216- 3.5 Hot Tap Length and Size
and the owner requirements. (a) Hot tap nozzle shall have sufficient length and size
(b) Hot taps shall be designed for the specified vessel, for the hot tap equipment to ensure a complete cut.
tank, or piping design pressure and temperature and other (b) Hot tap nozzle shall have sufficient length to permit
equipment loads. Piping flexibility analysis should be removal of flange bolts.
performed on connecting piping to determine the piping
loads acting on hot tap fittings. 216- 3.6 Hot Tap Location
(c) Hot tap fittings and reinforcement should be of the (a) Hot taps maybe performed in any position, or at any
same nominal chemical composition as the vessel, tank, angle around the pressure equipment, as long as there is
pipe, or branch material. sufficient room to perform the tap and install the fitting,
(d) The hot-tapped connection attachment welds should valve, and drilling machine.
be full penetration welds. (b) Hot taps should not be located on welded joints.
(e) A6-mm (1/4-in.) NPT venthole should be provided in Where installation on an existing weld seam cannot be
reinforcement pads and plugged with grease after all hot avoided, examination in accordance with para. 216- 5.1.3
tapping operations are completed. shall be completed before the hot tap installation.
(f) Hot taps NPS 2 and smaller should be self-reinforcing (c) Hot taps should be located
seamless nozzle, CL-6000 coupling, or welded-on fitting. (1) away from the weld seam (weld toe to weld toe)
(g) Gussets shall not be used for nozzle reinforcement by the lesser of the following lengths:
Gussets shall only be used to brace small bore connections (-a) 150 mm (6 in.)
when necessary. (-b) 8 times the wall thickness, t, of the header or
(h) Vents and drains used on hot tap connections for pressure equipment
purging and testing shall be positioned at high and low (2) at least sVkt from flanges, small bore connections,
points. and riveted joints, where R is the inside radius of the
(i) The diameter of a set-on-branch should be at least pressure equipment at the location of the hot tap, and t is the
one nominal pipe size smaller than the diameter of the run measured wall thickness.
pipe. In some cases, such as with line stop, a size-on-size The spacing between adjacent fittings listed in the
branch is required. Special care should be taken for these applicable design code for adjacent connections should be
hot taps to avoid the potential of the cutter inadvertently maintained. This can lead to larger separation between
cutting into or through the run pipe. adjacent connections.
216- 3.4 Full Encirclement Sleeves Design (d) If it is not possible to locate the hot tap away from
Requirements a welded seam, then it should be centered on the weld seam
(see para. 216-5.1.3).
(a) Hot taps should use a full encirclement sleeve when
the ratio of the diameters of the branch connection to the 216- 3.7 Hot Tap Orientation
run pipe connection is greater than 0.7. (a) Hot tap branch connections should be perpendicular
(b) Hot taps using full encirclement sleeves should be (90 deg) to the vessel or tank axis, or to run pipe.
fabricated in two half sleeves. The longitudinal weld seams (b) Hot tap connections made to an angle other than 90
should be positioned 90 deg away from the penetration. deg to the axis of the vessel or tank, or to run pipe, should be
(c) Longitudinal weld seams shall be joined by a full used only where other connections are not possible.
penetration groove weld designed to prevent welding
directly to the run pipe by using a backing strip or by
chamfering the back side of the weld preparation. A backing
strip shall be used for longitudinal seams in split sleeves.

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(d) The gasket between the hot tap machine and the
216-3.8 Coupon Retention and Contamination
valve should not project into the flow path such that it
During Hot Tapping interferes with the cutter. If a spiral-wound gasket is used,
the gasket shall have an inner ring.
216-3.8.1 Hot Taps Located on Top of Pipe NOTE: There have been incidents involving spiral-
(a) Hot tapping from the top side of the pipe has the wound gaskets without an inner ring where the cutter
highest probability of loss of the coupon and contamination. has caught the innermost winding of the gasket and
An acceptable method of coupon retention shall be used caused the gasket to unravel. This has resulted in a
with consideration given to product flow. gasket failure and release of the piping contents.
(b) Consideration should also be given to the
contamination of the pipe with metal shavings that fall into 216-3.10 Flow Rate and Minimum Liquid
the pipe and which can damage downstream equipment Level in Pressure Equipment for Hot
216-3.8.2 Hot Taps in Horizontal Position
Tap
(a) Procedures should be developed to ensure that there
(a) When choosing an angle at or below the horizontal
is adequate flow or liquid head in pressure equipment
position, the designer should consider the tendency of the during welding.
shavings or chips (from cutout) to fall into the block valve (b) An appropriate fluid flow rate should be maintained
affecting the operation and sealing of the block valve. in the pressure equipment that is being hot tapped to
Selection of an appropriate block valve can mitigate the minimize the risk of overheating the liquids. A minimum
adverse effect of shavings or chips. flow rate should be 0.4 m/s (1.3 ft/sec) for liquid and gas.
(b) When tapping in the horizontal direction where the
(c) For liquids, consideration should also be given to a
machine is parallel to the ground, the valve should be maximum flow during welding to minimize the risk of high
inverted, with the valve stem pointing to the ground, to hardness in the heat-affected zone due to fast cooling rate.
minimize the possibility of shavings or chips preventing the The maximum flow rate depends on the process
valve from seating properly. Such hot taps generally should temperature. The user should perform thermal modeling or
be considered temporary until the valve is righted. rely on established procedures, proven through successful
216-3.8.3 Hot Taps in Bottom Side of Pipe practice, to determine the appropriate maximum flow rate.
(a) Tapping from the bottom side has the lowest
There generally is no restriction on maximum flow rate for
probability of losing the coupon. gas lines.
(d) The flow rate during the cutting operation shall be
(b) There should be sufficient void space under the valve
maintained within the recommended limits of the hot tap
to allow for the cuttings to fall and to retract the cutting head
equipment.
through the valve.
(e) The liquid level in the vessels and tanks that have no
216-3.9 Hot Tap Valve flow should be maintained at least 1 m (3 ft) above the hot
(a] ) The hot tap valve should be full port API 600, or tap location.
equivalent valve with a pressure rating not less than that of NOTE: Insufficient liquid height or flow can result in
the run pipe and the branch pipe. flammable mixture during the welding operation
(f) If there is no flow, or if there is insufficient liquid
(1) The valve should match the highest flange rating of
the run pipe and the branch pipe. level above the hot tap, consideration shall be given to the
(2) The valve should also meet the piping material
effect of overheating the process liquids.
specification and grade for the more severe of the run pipe 216-3.11 Wall Thickness to Prevent Burn-
and the branch pipe. Through During Welding
(b) The hot tap valve packing shall be compatible with (a) Consideration shall be given to heat input, wall
the process service conditions. thickness, depth of weld penetration, and operating
(c) The hot tap drill diameter shall not interfere with
conditions when determining burn-through risk. The
valve seat rings. probability of burn-through increases when welding
(d) The inside diameter of the hot tap valve shall provide
components are less than 6.4-mm (1/4-in.) thick. To
sufficient clearance for the outside diameter of the cutter.
minimize the risk of burn-thorough for such welding
There should be at least 3 mm (1/8 in.) Clearance.
components, the first pass should be made with 2.4 mm (3/32
in.) or smaller diameter electrodes.
(b) The minimum pressure equipment wall thickness
for hot taps should be
(1) 4.8 mm (3/16 in.) for set-on-type fittings used for
hot tap connections

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(1) 4 mm (5 / 32 in.) for forged pressure retention tee-

type connections
(c) Welding of hot tap fittings should not be performed
on thinner walls unless justified by mock-up, engineering
analysis, or prior successful experience with similar welding
procedures. The inside surface temperature of
the vessel or pipe wall should he below 980°C (1,800°F)
during welding to prevent burn-through but this where
temperature can be excessive for some products (see paras. D = outside diameter
216-2.3 and 216-2.4). D1 = inside diameter
(d) The area to be welded for hot tap fittings on the T 1 = operating temperature during hot tap
vessel, pipe, or tank should be examined using UT scanning T 2 = 750°C (1,380°F), the assumed temperature in the depth
to ensure adequate thickness and soundness of the plate or of penetration plus recrystallization zone
pipe wall throughout the area to be welded. (6) Establish the yield strength of the component wall
(e) Welding of hottap fittings shall not be performed if at the calculated average metal temperature, T m .
there is not sufficient thickness to contain the internal (-a) The yield strength at temperature T m may be
pressure, and prevent burn-through in the vessel or pipe obtained from ASME Boiler and Pressure Vessel Code,
wall during welding. If there is insufficient thickness Section II, Part D, Table Y-1 for temperatures up to and
(1) the pressure should be reduced to a safe level to including 1,000°F (538°C). For some materials, the yield
allow in-service welding strength at higher temperatures can be found in published
(2) an alternative piping design should be considered, literature [see para. 216-7.3, reference [4]).
or (-b) The allowable design stress, S, for the
(3) the use of a mechanical connection may be component wall shall not exceed two-thirds of the yield
considered strength attemperature T m, the hot tap temperature in the
216- 3.12 Maximum Allowable Internal vessel or pipe wall.
Pressure for Welding of Hot Tap Fittings
216-3.13 Maximum Permissible External Pressure
(a) The maximum allowable internal pressure that is (a) The maximum allowable external test pressure
permitted during welding of the hot tap fittings shall be (without internal pressure] during the hot tap hydrostatic
calculated by the equation in the applicable construction testing on the pressure vessel, storage tank, or pipe wall
code or by an engineering analysis. shall be determined by use of the appropriate formula from
(b) The available thickness, the average metal the applicable construction code or post-construction code
temperature, and the allowable tensile stress during or standard, using the measured wall thickness and the
welding may be established as follows: maximum expected operating temperature of the hot-
(1) Calculate the wall thickness, t, available to contain tapped equipment
internal pressure as follows: (b) The assessment of the allowable external pressure to
t = measured wall thickness — 2.4 mm ( 3 / 32 in.) avoid buckling or plastic collapse may be calculated by use
of the procedures and equation in the original construction
as a margin to prevent burn-through. code or by one of the following methods:
(2) Adjust the outside diameter to be used in the (1) In hot taps employing full encirclement sleeves or
calculation as follows: split tees, the maximum allowable external pressure may be
D = pipe or vessel O.D. — 4.8mm(3/16 in.) determined by the requirements in ASME Boiler and
Pressure Vessel Code, Section VIII, Division 1, UG-28
(3) Let T1 = service temperature and = inside through UG-30, using the centerline length between the
diameter. circumferential welds between the split tee and the run pipe
(4) Assume the temperature in the depth of as length L, and the measured thickness of the pressure
penetration plus recrystallization zone is T 2 and equal to component, to calculate the ratio D/t (where D is the
750°C (1,380°F). outside diameter of the pressure component subjected to
external pressure and t is the measured thickness).
(5) Calculate the average temperature in the (2) For hot taps on cylinders employing set-on-type
remaining metal available for internal pressure nozzles with or without reinforcing pads, the maximum
containment, T m allowable external pressure to prevent buckling of the pipe
or vessel shell wall may be determined by the following
calculation:

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216-3.14.2 Piping Flexibility Analysis

(a) Consideration should be given to piping loads from
connecting piping systems.
(b) Piping flexibility analysis should be performed to
where
a = 1/2 sector angle of the arc of the hot-tapped determine the acceptability of imposed nozzle loads for
future operating conditions.
pipe, vessel, or tank shell within the inside diameter
(c) The installation of the new pressure equipment
of the hot tap fitting
should not increase the existing pressure equipment
Do = outside diameter
stresses beyond their allowable limits.
E = modulus of elasticity at test temperature
k = factor determined by iteration: k tan a cot 216-3.15 Piping Supports
ka = 1. Or
Adequate bracing or support should be provided for
piping to support the increased loads from the additional
weight added as a result of the hot tap, and to minimize
vibration or impact on the line during cutting.
M = design margin, taken as 3.0 or greater 216-3.15.1 Piping Transmitted Loads. A conventional
MAEP = maximum allowable external pressure pipe stress analysis should be performed to assess the
tmin = minimum measured wall thickness in test area effects of bending over supports from weight of the hot tap
v = Poisson’s ratio valve and additional valves or fittings, thermal expansion,
etc., unless these loads are determined to be insignificant
NOTE: This equation is valid for R/t > 10 (where R = the
radius of the vessel, pipe, or a storage tank, and t is its 216-4 FABRICATION
thickness).
(a) All connections should be welded to the vessel or
The allowable external pressure to avoid buckling or piping surface and examined, and pressure tested prior to
plastic collapse may also be assessed by calculating the cutting the hole.
critical buckling pressure on that part of the vessel shell or (b) NDE in lieu of pressure testing may be used only
pipe within the diameter of the new hot tap fitting by when agreed to by the owner and the inspection agency (if
generally accepted analytical methods or equations and by applicable).
applying a design margin consistent with the original
construction code to determine the allowable external 216-4.1 Welding
pressure.
216-4.1.1 General
(c) Consideration shall be given to the highest and the
lowest operating temperatures in making these (a) Welding materials shall be compatible with the
calculations. The use of the highest operating temperature materials to be welded.
will account for reduction in the strength at the higher (1) Consideration should be given to carbon
temperature. equivalents of the materials to be welded, heat inputs and
cooling rates to minimize the risk of developing cracks in the
216-3.14 Pressure Equipment Stresses weld metal and heat-affected zones after welding.
From Applied Loads on Hot Tap Nozzles (2) See Article 210 for additional welding
Connections should be designed to prevent considerations.
overstressing of the pipe or vessel being hot tapped due to (b) In-service welding requires additional
the conditions specified in paras. 216-3.14.1 and 216-3.14.2. considerations, such as adequate preheat, gas purge (with
216- 3.14.1 Hot Tapping Loads dry air, C02, etc.), low hydrogen welding consumables, and
special welding procedures to prevent moisture and reduce
(a) During hot tapping, the weight of the hot tap valve
high weld quench rates to avoid the potential for cracking of
and the drilling machine, if not independently supported,
welds.
could bend the pressure equipment and possibly buckle the
(c) Flame heating should not be used.
pressure equipment wall at the base of the branch.
(b) If the branch is not in the vertical plane, the 216-4.1.2 Qualifications. Welding procedures and
cantilevered weight of the valve and the drilling machine welders or welding operators shall be qualified in
will apply a bending moment to the pressure equipment accordance with the applicable construction code or
(c) The stresses induced by these loads should be postconstruction code.
calculated, multiplied by an appropriate dynamic factor
(e.g., 2.0), and combined with the internal pressure stresses.

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216-4.1.3 Welding Practices. The following welding (7) owner approval to remove the drilling equipment
practices should be followed: from the hot tap valve
(a) Low hydrogen consumables or processes (8) verification of flow rate in piping
should be used. For root passes, other electrode (c) The cutout coupon should be delivered to the owner
types may be used, provided they match the representative as evidence of the coupon removal. It is also
nominal chemical composition of the base metal useful to provide the coupon to the owner’s inspection
and do not significantly increase the risk of department for verification of pipe wall thickness and
burn-through or hydrogen cracking. internal pipe condition for their records.
(b) Small weld beads [2.5 mm (3/32 in.) maximum
electrode diameter if SMAW is used] and a 216-5 EXAMINATION
stringer bead technique with a maximum of 3 216-5.1 Pre-Hot Tap Examination
times the electrode core diameter should be
used for all welds on pressure parts to minimize 216-5.1.1 General
the heat input on the first passes. (a) The area to be hot tapped in the vessel or pipe shall
(1) Larger diameter electrodes may be considered for be examined using UT scanning, unless limited by
fill passes if the wall thickness is greater than or equal to 1/2 temperature, to determine the existing thickness and any
in. (13 mm). defects of the plate or pipe wall.
(2) Layer or bead thickness should be restricted to 5 (b) Hot taps should not be made in the areas where the
mm (3/16 in.) to promote interbred or layer tempering. measured thickness is less than the minimum thickness
(c) Minimum amperage consistent with achieving required for welding or in areas where defects exist in the
an acceptable weld should be used. vessel wall or pipe wall (laminations, etc.).
(d) Buttering or weld overlaying the pipe or vessel (c) Existing defects need not be removed if located in the
surface prior to attaching a nozzle to 19-mm pipe or vessel material that will be removed during the hot
(3/4-in.) thick or heavier pipe fabricated from tap operation.
plate should be considered to prevent lamellar
tearing of the header pipe or vessel. See ASME 216-5.1.2 MT and PT Examination
Boiler and Pressure Vessel Code, Section IX.
(a) The area to be hot tapped should also be examined
(e) For metal temperatures below the dew point, or
when welding could result in increased by the MT or PT methods to check for surface defects where
hardness, preheating or surface heating may be the examination in para. 216-5.1.1(a) indicates surface
required to reduce the risk of hydrogen-induced damage (e.g., corrosion, pitting), unless MT or PT is limited
cracking. by the operating conditions.
(f) All welds shall be within the design (b) The acceptance criteria for MT and PT should be in
requirements of the fitting. accordance with the original construction code. If there is no
acceptance criteria listed in the original construction code,
216-4.2 Execution of the Hot Tap the criteria listed in ASME Boiler and Pressure Vessel Code,
Section VIII, Division 1 may be used.
(a ) Hot tap drilling equipment shall only be operated
by qualified and experienced personnel. 216-5.1.3 Weld Seam Preparation
(b) The equipment user shall establish procedures for
execution of the hot tap cutting operation. It is (a) If the hot tap is to be located on an existing weld seam
recommended that such procedures include and if not limited by the maximum allowable temperature
(1) verification that the equipment is suitable for the for the intended examination techniques, then the existing
application weld seam should be ground flush.
(2) establishing the drilling machine boring bar travel (b) The weld seam should be subjected to 100% of
distances for the drill and cutter entry into the pipe volumetric examination (e.g., UT) and 100% surface
(3) owner approval to commence cutting operation examination (e.g., MT or PT) of the external surface in the
(4) purging if necessary to eliminate air from the area of the hot tap and for 75 mm to 100 mm (3 in. to 4 in.)
equipment prior to cutting on each side of the hot tap to ensure that there are no
(5) detailed operational steps for completing the detectable flaws in the area to be welded.
cutting operation that includes 216-5.1.4 Covered Longitudinal Welds.
(-a) verifying the boring bar positions for drill and Longitudinal welds in the pipe that will be covered by full
cutter match those calculated prior to commencing the encirclement sleeve or reinforcing pad shall be examined by
equipment operation radio- graphic or ultrasonic examination prior to installing
(-b) verifying the pilot drill engagement to the the hot tap, unless limited by the operating conditions.
coupon
(-c) verifying the coupon cutout has been
completed
(6) methods for product venting or containment on
completion of the cutting operation

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216-5.2 Hot Tap Fitting Field Welds

(a) All welds should be examined by the UT method, (2) Prior to performing the pressure test, the
where possible, and by MT or PT methods after maximum pressure of the pressure test shall be confirmed
completion of welding. to be less than the maximum permissible external pressure
(b) The root and the final passes of the nozzle-to- as specified in para. 216-3.13.
header and nozzle-to-flange welds shall be 100% MT or (b) When the cut is to be performed immediately after
100% PT examined, where possible, before applying any the pressure test, the pressure test may be
required reinforcement performed with the hot tap valve and cutting
(c) The acceptance criteria shall be in accordance equipment in place.
with the applicable construction code. (c) When it is not possible or practical to perform the cut
immediately after the pressure test is performed, the
216-5.3 Hot Tap Fitting Shop Fabrication Welds pressure test may be performed without the hot tap
(a) All full penetration, pressure-retaining welds valve and cutting equipment in place.
made in shop shall be 100% RT or 100% UT examined in (1) A follow-up leakage test shall be performed prior
accordance with the applicable construction code. to the cut, which includes the hot tap valve and cutting
(b) All other welds shall be 100% MT or 100% PT equipment in place to ensure that there has been no damage
examined. to the fitting and the cutting equipment, and to verify the
flange joint assembly.
216-6 PRESSURE TESTING (2) This leakage test shall be equal to or greater than
the operation pressure of the vessel or pipe but not exceed
216-6.1 Cutting Equipment maximum permissible external pressure on the vessel or
(a) The cutting equipment should be subjected to a pipe or maximum test pressure allowed by the hot tap valve
pressure test prior to the hot tap cutting operation to or cutting equipment
ensure that the equipment has no leaks when under (d) Where a pressure test is determined not to be
pressure. practical or advisable by subject matter experts and the full
(b) This pressure test should be performed NDE specified in paras. 216-5.1 and 216-5.2 has been
independently by the operator of the cutting equipment satisfactorily completed, the appropriate subject matter
prior to the start of the hot tap operation. experts may waive the need for a pressure test as allowed
(c) The pressure test to be performed on the cutting the original construction code and/or the repair/alteration
equipment shall be equal to or greater than the specified post-construction code.
test pressure for the hot tap fitting, but not greater than
the maximum test pressure allowed by the cutting 216-6.4 Pressure Test Medium
equipment design. (a) For operating temperatures of the vessel or pipe in
the range 0°C to 90°C (32°F to 200°F), water should be used
216-6.2 Hot Tap Valve to perform a hydrostatic test
(b) At temperatures outside this range, an alternative
(a) The hot tap valve should be subjected to a
pressure test prior to the hot tap cutting operation. fluid such as a light oil, antifreeze, or silicone may be used to
(1) This pressure test should be performed
perform a hydrostatic test Some possible alternative
independently by the valve manufacturer, or the hydrostatic test fluid are as follows:
(1) For operating temperatures in the range -40°C to
owner/user of the equipment, or the equipment operator
prior to the start of the hot tap operation. 0°C (-40°F to 32°F), a 70% ethylene glycol and water
(2) The pressure test to be performed on the valve
solution should be used.
shall be equal to or greater than the specified test (.2) For operating temperatures in the range 90°C to
pressure for the hot tap fitting, but not greater than the 115°C (200°F to 240°F), steam or industrial grade ethylene
maximum test pressure allowed by the valve design. glycol may be used.
(3) For operating temperatures in the range 90°C to
216-6.3 Hot Tap Fitting — General 290°C (200°F to 550°F), an appropriate grade of turbine oil
Considerations may be used, or an appropriate grade of silicone fluid may
be used.
(a) The hot tap fitting should be subjected to a test (c) For operating temperatures of the vessel or pipe over
pressure above the design pressure after welding 290°C (550°F), pneumatic test with nitrogen gas may be
but prior to cutting the hole in the header, or the used.
vessel wall, or the tank wall. (d) Consideration should be given to compatibility of the
(1) This pressure test may be a hydrostatic test or test medium with the component materials. For
a pneumatic test example, the chloride content of test water generally
should not exceed 50 ppm when working with
stainless steel.

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216-6.5 Hydrostatic Testing of Hot Tap Fittings Publisher: American National Standards Institute [ANSI],
25 West 43rd Street, New York, NY 10036
216-6.5.1 Test Pressure [www.ansi.org]
(a) The hydrostatic test pressure should be performed
at a test pressure that is at least the test pressure required API Standard 510, Pressure Vessel Inspection Code:
by the original construction code or the applicable Maintenance Inspection, Rating, Repair, and Alteration
postconstruction code, but not greater than the lesser of API Standard 570, Piping Inspection Code: Inspection,
following: repair, Alteration, and Rerating of In-Service Piping
(1) The lesser of 1.5 times the design pressure of the Systems
line, or vessel, or tank, and 1.5 times the flange pressure- API Standard 600, Steel Gate Valves — Flanged and Butt-
temperature rating listed in ASME B16.5 at the test Welded Ends, Bolted Bonnets API RP 941, Steels for
temperature for hot tap fittings installed on a system which Hydrogen Service at Elevated Temperatures and
includes B16.5 flanges. Pressures in Petroleum Refineries and Petrochemical
(2) The maximum permissible external pressure on Plants
the vessel or pipe (see para. 216-3.12) inside the hot tap API RP 2009, Safe Welding, Cutting, and Hot Work
fitting at the test temperature. Practices in Petroleum and Petrochemical Industries
(b) The test medium shall be selected such that local Publisher: American Petroleum Institute [API], 1220 L
boiling of the test medium does not occur when subjected to Street, NW, Washington, DC 20005 [www.api.org]
operating temperature of the vessel or pipe [see para. 216- MSS SP-97-2006, Integrally Reinforced Branch Outlet
6.4(a)]. Fittings-Socket Welding, Threaded, and Butt Welding
216-6.6 Pneumatic Test of Hot Tap Fittings Ends
Publisher: Publisher: Manufacturers Standardization
(a) Pneumatic test should not be used because of the
Society of the Valve and Fittings Industry, Inc. [MSS],
increased risk of stored energy.
127 Park Street, NE, Vienna, VA 22180
(b) it is sometimes necessary to consider a pneumatic
[www.msshq.org]
test if it is not practical to perform a hydrostatic test (e.g.,
for test temperatures above the boiling point of water or
other liquids). 216-7.2 Related Codes and Standards
(c) A pneumatic test with air or other gases (e.g., The following is a list of publications referenced in this
nitrogen] should only be performed when agreed to by the Article. Unless otherwise specified, the latest edition shall
owner. apply.
(d) The pneumatic test pressure shall not exceed 1.1
ASME Boiler and Pressure Vessel Code, Section V,
times the pressure rating of the hot tap fitting at the
Nondestructive Examination ASME ASME B31.1, Process
operating temperature of the vessel or the pipe.
Piping ASME ASME B31.3, Power Piping ASME ASME
(e) See Article 501 for extensive guidance on performing
B31.4, Pipeline Transportation Systems for Liquid
pneumatic test
Hydrocarbons and Other Liquids ASME ASME B31.8, Gas
216-7 REFERENCES Transmission and Distribution Piping Systems
216-7.1 Referenced Codes and Standards Publisher: The American Society of Mechanical Engineers
[ASME], Two Park Avenue, New York, NY 10016-5990
The following is a list of publications referenced in this
[www.asme.org]
Article. Unless otherwise specified, the latest edition shall
apply. ANSI Z49.1, Safety in Welding, Cutting and Allied
Processes
ASME Boiler and Pressure Vessel Code, Section VIII,
Publisher: American National Standards Institute [ANSI],
Division 1Rules; for Construction of Pressure Vessels ASME
25 West 43rd Street, New York, NY 10036
Boiler and Pressure Vessel Code, Section IX, Brazing, and
[www.ansi.org]
Fusing Procedures; Welders; Brazers; and Welding,
Brazing, and Fusing Operations ASME B16.5, Pipe Flanges API RP 577, Recommended Practice, Welding Inspection
and Flanged Fittings Publisher: The American Society of and Metallurgy
Mechanical Engineers [ASME], Two Park Avenue, New API RP 582, Recommended Practice, Welding Guidelines
York, NY 10016-5990 [www.asme.org] for the Chemical, Oil, and Gas Industries API Standard
620, Design and Construction of Large, Welded, Low-
ANSI/NB-23 National Board Inspection Code, Part 3, Pressure Storage Tanks API Standard 650, Welded Steel
Repairs and Alterations. Tanks for Oil Storage

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API Standard 653, Tank Inspection, Repair, Alteration, and 216-7.3 Related Technical Publications
Reconstruction (1) Piping and Pipeline Assessment Guide, A. Keith Escoe,
API RP 2201, Safe Hot Tapping Practice 2201 Publisher: Section 7, Hot Tapping.
American Petroleum Institute (API), 1220 L Street, NW, [2] Relaxation of In-Service Welding Procedure Flow
Washington, DC 20005 (www.api.org) Restrictions, by M. A. Boring and Joe Sobilo,
Proceedings of IPC2008, 7th International Pipeline
NFPA 5 1B, Standard for Fire Prevention During Welding, Conference, September 29 - October 3, 2008, Calgary,
Cutting, and Other Hot Work Publisher: National Fire Alberta, Canada.
Protection Association (NFPA), 1 Batterymarch Park, [3] Roark's Formulas for Stress and Strain, Eighth Ed., W. C.
Quincy, MA 02169-7471 (www.nfpa.org] Young, R. D. Budinas, and A. M. Sadegh.
[4] Steels for Elevated Temperature Service, United States
Steel, 1974 Edition.
[5] Welding Metallurgy, Second Edition, Sindo Kou.

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NONMANDATORY APPENDIX 216-A

GLOSSARY OF ACRONYMS
216-A-1.2 Terms
216-A-1 GLOSSARY OF ACRONYMS 216-A-1.1 BPVC Boiler and Pressure Vessel Code
IPC International Pipeline Conference
Organizations
API American Petroleum Institute MT Magnetic particle testing
ASME The American Society of Mechanical NPS Nominal pipe size
Engineers NPT National pipe threads
MSS Manufacturers Standardization Society of the
Valve and Fittings Industry PT Liquid penetrant testing
NB National Board PWHT Post weld heat treatment
NFPA National Fire Protection Association RP (API) recommended practice
Swarf Cutout produced during the cutting
operation
UT Ultrasonic testing

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Article 304
Flaw Excavation and Weld Repair
303- 1 DESCRIPTION 304- 2.2.2 Grinding or cutting consumables used on
carbon or low alloy steel materials will become
Surface flaws see Figure 304-3.1-1, or embedded flaws
impregnated with residues of those materials and become
see [Figure 304-3.1-2, illustration (a]] in base material or
unsuitable for use with austenitic stainless steels. Abrasive
welds that exceed the allowances of the applicable
cutting or grinding consumables should be segregated for
construction code or post-construction code can be
use on carbon and low alloy steels from those used for
removed by excavation [see Figure 304-3.1-1, illustration
austenitic stainless steel substrates. Surface contamination
(b) ; and Figure 304-3.1-2, illustration (b)]. The
of austenitic stainless steel with carbon or low alloy steel
remaining cavity can be filled with weld filler metal [see
residues can result in surface corrosion or pitting of the
Figure 304- 3.1-1, illustration (c); and Figure 304-3.1-2, austenitic stainless steel. To avoid such problems, only
illustration grinding wheels designated as austenitic stainless steel
(c) ], or left as-is, under conditions described in this grinding wheels shall be used on these materials.
Article. Depending on the type and location of the flaw,
and the type of base metal or weld material, excavation 304- 2.2.3 When grinding out stress corrosion cracks
can be accomplished by mechanical removal methods in stainless steel, or in the case of steels that have suffered
[grinding, machining, lapping, honing, or flapping], or by from anodic stress corrosion cracking (such as amine or
thermal removal methods (thermal gouging). causticstress corrosion cracking), it is necessary to qualify
Descriptions of these excavation techniques are provided and control the amount of heat generated to avoid making
in Mandatory Appendix 304-I. the cracks deeper and longer as a result of excessive heat
Steel contaminated with caustic or amines can also recrack
303- 2 LIMITATIONS during welding repairs or thermal cutting. Appropriate
cleaning procedures shall be used prior to excavation or
303- 2.1 Additional Requirements repair.
Part 1 of this Standard contains additional 304- 2.2.4 In tight spaces, burring tools may be used
requirements and limitations. This Article shall be used in in place of grinding wheels.
conjunction with Part 1.
304- 2.3 Machining
304- 2.2 Grinding When cutting fluids are used, care shall be taken to
304-2.2.1 Grinding wheels shall not be forced or prevent their contact on surfaces where they may be
overloaded, in order to avoid the safety hazards from detrimental. Furthermore, chips of the machined metal
wheel failure. Furthermore, overloading the shall be controlled and kept from entering components
grinding wheel can cause areas of localized high where their presence can be detrimental.
temperature in the substrate being ground, leading in 304- 2.4 Honing
some cases to the formation of brittle untempered
The honing speeds shall be adjusted as a function of
martensite, or tight, shallow surface cracks. Abusive
length-to-bore ratio of the component and its material
grinding and uneven and rough finish can result in
hardness.
reduced fatigue strength or premature failure due to the
introduction of large surface residual tensile stresses and 304- 2.5 Flapping
stress risers. These problems normally can be avoided by 304-2.5.1 Flapping should only be used to smooth or
using lighter grinding practices that avoid surface polish a surface. Flapping is unsuitable for removing defects
oxidation, evident through discoloration. It may be other than superficial surface blemishes.
necessary to preheat some high strength alloy steels prior
to grinding. Grinding wheels are manufactured to be used 304-2.5.2 The abrasive marks of the flapper should
on specific materials (ferritic or austenitic steels, be directed perpendicular to the direction of the preceding
masonry, etc.). Therefore, only grinding wheels pass. Marks of the preceding pass should be removed prior
specifically designed to work on the material being
ground shall be used. Rotary files should be considered
for nickel alloys.

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to proceeding to the next finer grit In this way, distortion of

the surface will be minimized and smooth surfaces can be
obtained.

304-2.6 Thermal Gouging

304-2.6.1 When thermal gouging by carbon arc or
plasma arc, the very rapid heating to molten temperatures
and subsequent quenching to ambient temperature can
result in hardened or brittle heat-affected zones. This
thermally affected material should be subsequently
removed by a mechanical process, such as grinding.
304-2.6.2 For some materials it may be necessary to
preheat the metal prior to arc gouging in order to prevent
cracking, in particular materials that are required to be post
weld heat treated by the construction code or post-
construction code.
304-2.7 Generalized Damage
This repair technique applies well to local defects.
Where damage is extensive, such as general stress
corrosion cracking of stainless steel, replacement should be
considered.

304-3 DESIGN
304-3.1 Excavation Without Weld Deposit
Material or weld flaws open to the surface [Figure 304-
3.1-1, illustration (a)] or embedded flaws [Figure 304-3.1-
2, illustration (a)] are typically removed by a mechanical
(abrasive) method (Figure 304-3.1-3). If the remaining wall
thickness of the excavation, with allowance for future
corrosion, is greater than the minimum required wall
thickness required by the applicable construction code or
post-construction code, such as the local thin area rules of
API 579-1/ASME FFS-1, then the excavated area may be
blended to a 3:1 or smoother profile slope, and left as-is for
return to service.
304-3.2 Weld Deposition
When the removal of a flaw produces a remaining wall
thickness below the limit permitted by the applicable
construction code or post-construction code, including
allowance for future corrosion, then the cavity shall be
repaired by deposition of weld metal [Figure 304-3.1- 1,
illustration (c] and Figure 304-3.1-2, illustration (c)] or
analyzed for fitness-for-service. When the depth of material
excavated necessitates a weld repair, the cavity shall be
prepared for welding. Either during or following defect
removal, the excavation shall be shaped to provide
adequate access for the welding operation in order to
facilitate proper fusion, and avoid slag entrapment, or lack
GENERAL NOTE: of penetration. To minimize weld shrinkage stresses, the
A 3-to-l taper is not required when the cavity will be filled with weld width of the cavity should only
metal.

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 ASME PCC-2-2018

Figure 304-3.1-3 Grinding of Weld Flaw

be as wide as needed to ensure defect removal and to 304-4.1.3 Verify defect removal by inspecting the cavity
facilitate welding as previously described. using visual examination (VT) and liquid penetrant testing
(PT), magnetic particle testing (MT), or eddy current testing
304-3.3 Mechanical Excavation
(ET) as appropriate. Measure the remaining wall thickness
If the excavation is performed using a thermal removal of the excavated cavity using an approved thickness
process [carbon arc or plasma arc gouging), an additional measurement technique. If remaining is greater than the
1.5 mm (Vi6 in.) of material shall be removed by a minimum required thickness as determined by a fitness-
mechanical removal process such as grinding, prior to the for-service evaluation, the excavation cavity need not be
final inspection and before welding begins. This is filled with weld deposit, as provided in para 304-3.1.
necessary to remove any surface cracks, hardened material,
scale, or carbon deposit 304-4.1.4 When required by design (section 304-3),
repair the cavity by welding according to a qualified
304-4 FABRICATION welding procedure specification (WPS), using a qualified
welder, as required by the applicable construction code or
304-4.1 Repair Steps
post-construction code.
The requirements specified in paras. 304-4.1.1 through
304-4.1.5 are generally followed to excavate a flaw. . 304-4.1.5 Perform preheat or post weld heat treatment,
when required by the applicable construction code or
304-4.1.1 Locate and expose the flaw. Characterize the flaw
post-construction code, as indicated by owner- user
(size, depth, orientation) to the extent possible. If the flaw is
specification, or as dictated by service conditions.
a crack, the crack tips may be rounded by drilling to
preclude crack from propagating during its excavation. 302- 4.2 Special Fixtures
304-4.1.2 Remove the flaw by grinding, machining, honing, In some cases, special fixtures may be required to
or thermal gouging. In selecting and applying a removal accomplish precision work. In addition, it is often
process, refer to the guidance in sections 304- 2 and 304-3. beneficial to develop special gages to monitor the depth
of metal removal and to prevent excessive material from
being removed. Special contour templates or common
carpenter gages may be used and may be integrated into
special fixtures.

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304- 6.2 Test Method

304-4 EXAMINATION If a leak test is performed, it may be hydrostatic,
pneumatic, sensitive leak, or in-service as required by
304-5.1 Critical Service
the applicable construction code or post-construction
In critical service applications, following a local repair, code.
the final surface and adjacent area shall be examined using
VT and PT, MT, or ET, in accordance with the defect 304- 6.3 Exemption
acceptance criteria of the applicable construction code or When the excavation does not fully penetrate the
postconstruction code. component pressure boundary, leak testing may be
waived.
304- 5.2 Volumetric Examination
304- 7REFERENCES (18)
Volumetric examination (RT or UT) shall be considered
The following is a list of publications referenced in
where there is a possibility of flaws introduced during
this Article. Unless otherwise specified, the latest
repair welding, such as shrinkage cracks from deep weld
edition shall apply.
repairs in thick sections.
ANSI B7.1, Safety Requirements for the Use, Care and
304- 5.3 Additional Examinations Protection of Abrasive Wheels ANSI B74.2,
Additional examinations shall be performed if required Specifications for Shapes and Sizes of Grinding
for similar welds by the applicable construction code or Wheels, and for Shapes, Sizes and Identification of
post-construction code. Mounted Wheels
ANSI B74.13, Markings for Identifying Grinding
304- 6 TESTING Wheels and Other Bonded Abrasives Publisher:
American National Standards Institute (ANSI),
304- 6.1 Applicability 25 West 43rd Street, New York, NY 10036
Generally, and unless specified otherwise in the (www.ansi.org)
applicable construction code or post-construction code,
API 579-1/ASME FFS-1, Fitness-for-Service
weld repairs that have fully penetrated the component wall
Publisher: American Petroleum Institute (API), 1220
should be subjected to either leak testing or volumetric
L Street, NW, Washington, DC 20005 (www.api.org)
examination, or both, following the repair and any post
weld heat treatment to verify the integrity of the repair.

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Mandatory Appendix 304-I

Metal Removal Process

304- I-1 FLAPPING (b) Honing tools are placed in the bore of the component
and a radial load is applied such that the honing stones are
Flapping is a metal removal process involving a rotating
in contact with the bore surface. The hone is then rotated in
tool fabricated of abrasive papers. Flapper wheels come in
the bore, generating a high-quality surface.
a variety of grit sizes and should be worked from the more
(c) Honing stones generally are manufactured of
coarse grit to the finer grit
aluminum oxide, silicon carbide, or diamond abrasive grits,
304- I-2 GRINDING held together by vitrified clay, resin, or a metal bond. The
grain and grade of abrasive to be used is based on the
(a) Grinding is the process of abrading the surface of a amount of stock to be removed and the surface finish
material for the purpose of removing portions of the desired. Silicon carbide is generally used for cast iron, while
material. The process is used to remove localized cracks, aluminum oxide is generally used on steel. As with grinding
pits, deposits, hardened surfaces, etc. Equipment used for discs and lapping compound, the finer the grit, the finer the
grinding includes pencil or small disc grinders to remove surface finish.
local defects, and large disc or wheel grinders to remove
larger defects. The grinding equipment can be electric or 304- I-4 LAPPING
air-driven; with wheels of various shapes, sizes, and
(a) Lapping is a polishing technique that can be used to
abrasive characteristics.
prepare surfaces requiring a very smooth finish. Lapping is
(b) Every grinding wheel has two constituents: the
not economical for removing deep defects. A general rule of
abrasive that does the cutting and the bond that holds the
thumb is that lapping methods are suitable for shallow
abrasive component. Variations of these components can be
defects less than 0.05 mm (0.002 in.). Defects located
selected to give a wide range of grinding characteristics. The
greater than this depth should be removed by other
three American National Standards Institute (ANSI)
methods.
standards that provide specifications for grinding wheels
(b) Lapping machines are available as portable or
are as follows:
bench-type systems. In many cases, lapping is performed
(1) ANSI B74.13, Markings for Identifying Grinding
with special discs or plates made specifically for a given
Wheels and Other Bonded Abrasives
type of application. These plates are normally very thick to
(2J ANSI B74.2, Specifications for Shapes and Sizes of
maintain dimensional stability. After defect removal, the
Grinding Wheels, and for Shapes, Sizes and Identification of
surface should be lapped to the finish and dimensions
Mounted Wheels
specified by the design.
[3) ANSI B7.1, Safety Requirements for the Use, Care
and Protection of Abrasive Wheels 304- I-5 MACHINING
(c) Manual grinding is generally divided into one of
three categories: (a) Machining using portable equipment can provide for
(1J rough grinding — relatively rapid removal of defect removal and weld preparation in a single step.
excess weld metal or base material using coarse abrasives Machining with mechanized cutting equipment is used to
(2) polishing and blending — achieving a semismooth remove defects with precision. Machining equipment used
finish, using medium abrasives to remove defects or prepare a surface for repair include
(3) buffing — achieving a lustrous and reflective boring bars, milling machines, magnetic drills, flange facers
finish, using fine abrasives usually in a paste or liquid [portable lathes], and pipe cutting and beveling machines.
vehicle Machining has the advantage of cutting and forming the
weld preparation with a single piece of equipment while
304- I-3 HONING closely controlling dimensional tolerances.
(a) Honing is an abrasive process that is used to obtain
a fine finish on the inside surface of a cylindrical component

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(b) Portable boring bars have been used where (a) Boat sample cutters can be air powered or electric
circumferential machining of a bore is required, such as in motor driven. They are portable devices that are easily
valve maintenance. Other bars are available with mounted on the surface of the material to be excavated
accessories to by means of four anchoring bolts welded to the surface.
grind or mill unique geometries, and to drill and tap stud Shim spacers are used to adjust the width and depth of cut
holes. by controlling the space between the saw mounting frame
(c) Portable milling machines can be used to remove
and the surface of the plate.
localized materials at a faster rate than machines mounted
(b) Once securely mounted on the anchor bolts, the
on the component outer or inner diameters. Small milling
cutting process begins by making a single cut at the edge of
machines have been developed to operate in relatively
the material to be excavated. The curved blade is fed into
restricted locations.
the material until the desired depth is achieved and the saw
(d) Machining generally involves the use of cutting
circumference is at right angles to the joint The blade is then
fluids that perform several functions including lubrication,
retracted, the saw rotated 180 deg and a second cut is made.
cooling, and chip removal.
The two cuts meet automatically in the same plane and the
304- I-6 THERMAL GOUGING excavation is complete.
(c) Boat samples can be cut either longitudinal or
(a) In situations where defects are found to be extensive transverse with respect to the weld joint They are boat
and where accuracy is not critical, thermal gouging (carbon shaped and the cut sides have a spherical curvature. The
arc gouging or plasma arc gouging] can be used size varies in proportion to the thickness of the plate being
effectively. cut; however, specimens can range from a small size of 1/8
(b) Thermal gouging techniques are thermal removal in. depth x 23/8 in. length x 3/8 in. width to a large size of 1 in.
processes that involve localized melting of the metal, which depth x 43/4 in. length x 1/2 in. width. Larger specimens can
is quickly swept away by the force of high velocity air or gas be excavated with specially designed equipment.
jets. (d) The excavated boat samples are large enough to
allow for various mechanical testing processes. Cross
304- I-7 BOAT SAMPLE CUTTING sections of the "boats” can be used for hardness testing or
(a) Boat samples are metal samples in the shape of a metallographic inspection. Full-length specimens can be
boat hull that are cut out from base metal, weldments, or machined for tensile testing, bend testing, or Charpy V-
weld heat-affected zones (Figure 304-I-7-1). The process notch impact testing.
(e) Once the boat sample has been removed, the cutter
can be used for removal of weld defects, but is more
can be detached from its mounted position and the anchor
commonly used for obtaining samples of base materials or
bolts can be removed from the plate surface. The cavity left
welds for metallurgical or mechanical testing.
by the removal of the excavated boat sample is very
Boat sample cutters, sometimes referred to as weld
conducive to repair welding. The tapered nature of the
probers or trepanning machines, are mechanical
cavity ends and the sloping curvature of the cavity walls
devices designed to remove a portion of a weld or metal
allow complete and easy access for most welding processes.
plate by saw cutting from the plate surface. The machine
is a saw with a dished shape blade, capable of excavating
and removing a boat-shaped specimen from a flat surface
in any position.

131
ASME PCC-2-2018

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 ASME PCC-2-2018

Article 305
Flange Repair and Conversion
305-2.4 Residual Stress
305- 1 DESCRIPTION
The machining of weld over layed or weld built-up
305- 1.1 Introduction surfaces that have not been stress-relieved may cause the
This Article applies to the refinishing of flange faces to redistribution of residual stresses and subsequent
repair mechanical imperfections or damage from corrosion dimensional distortion over time. In such instances,
or other damage in service, or to changing the flange face precautions such as performing a stress-relieving heat
finish to enable the use of a different gasket. The surface treatment prior to finish machining shall be considered to
finish of a flange contact surface is essential to the leak ensure final dimensional stability.
tightness of the gasketed joint. When surface finish 305- 3 DESIGN
deteriorates in service, it can become necessary to either
replace the flange or refinish the flange face. 305- 3.1 Raised Face
305- 1.2 Work Location Under-thickness of a raised face due to refinishing shall
be acceptable, provided the minimum finished height of the
The repair can be performed in situ using a portable raised face is 0.8 mm (0.031 in.).
machine tool, or the pipe section or equipment containing
the damaged flange can be removed and repaired in the 305- 3.2 Thickness Evaluation
shop. If flange refinishing necessitates removal of material
from other than the raised face such that the flange
305- 2 LIMITATIONS
dimensions no longer comply with the original design
305- 2.1 Additional Requirements dimensions minus the original corrosion allowance or the
requirements of an applicable specification or standard, the
Part 1 of this Standard contains additional requirements
flange shall be evaluated to ensure that the removal of
and limitations. This Article shall be used in conjunction
material does not compromise design integrity. Design
with Part 1.
evaluation methods of an applicable new construction code
[such as ASME BPVC, Section VIII, Division 1, Mandatory
305- 2.2 Recurrence of Damage
Appendix 2), or an applicable post-construction code or
Flange refinishing will restore the flange facing but may standard shall be used.
not eliminate the cause of the initial imperfection or
damage. Therefore, the imperfection or damage may recur. 305- 3.3 Finish and Flatness
Consideration shall be given to the possible recurrence of The gasket seating requirements in terms of flange
the original imperfection/damage mechanism. surface finish and flatness shall be considered.
305- 2.3 Remaining Thickness 305-3.3.1 Flatness. For example, API 660 and TEMA
permit deviations from flatness that exceed those that are
The flange may not be sufficiently thick to permit metal recommended for certain gasket types of materials (e.g., flat
removal by machining and still meet the minimum metal). For guidance on flange face flatness tolerance, refer
thickness required for the design pressure rating. In such a to ASME PCC-1, Nonmandatory Appendix D.
case, it will be necessary to increase the flange ring
thickness by weld metal buildup before remachining the 305-3.3.2 Finish. See TEMA Fig. F-4 for permissible
surface. As an alternative solution, a split ring flange may be imperfections in flange-facing finish. The choice of flange-
added to the back of the existing flange to compensate for facing finish shall be in accordance with the applicable
reduced flange ring thickness, where geometry and spacing standard and compatible with the requirements specified
permits, and as qualified by the appropriate design by the user or recommended by the gasket manufacturer.
calculations. For example, unless otherwise agreed to

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 ASME PCC-2-2018

by the purchaser or manufacturer, ASME B16.5 specifies the 305-4.4 Machining

following flange-facing finishes (as judged by visual The cutting tool radius and feed rate should be set to
comparison with Ra standards per ASME B46.1): prequalified values in order to consistently achieve the
(a) Tongue and groove and small male and female desired surface finish. For minor imperfections, careful
flanges: not to exceed 3.2 pm (125 pin.) roughness. filing may be adequate for the removal and dressing of the
(b) Ring joint: not to exceed 1.6 pm (63 pin.) roughness. flange faces.
(c) Other: Either a serrated concentric or serrated
spiral finish having a resulting surface finish from 3.2 pm to 305- 4.5 Conversion of Flange Facing
6.4 pm (125 in. to 250 in.) average roughness shall be From Ring- Type Joint to Raised Face
furnished. The cutting tool employed should have an
Ring-type joint flanges may be converted to raised face
approximate 1.5 mm (0.06 in.) or larger radius and there
type flanges with the following considerations along with
should be from 1.8 grooves/mm to
relevant sections of this Article. The decision to convert to
2.2 grooves/mm (45 grooves/in. to 55 grooves/in.).
raised face flanges can result from observed or potential
305- 4 FABRICATION ring groove cracking or other reasons. One method of
conversion is performed by welding new material into the
305- 4.1 Repair Without Welding ring groove and machining to meet the raised face
If either the flange ring thickness or hub dimensions, or dimensions as called out in the applicable standard. Special
both, are sufficient, then the entire gasket surface may be conversion gaskets that can be used with an unmodified
machined to remove the area of degradation or ring joint flange may also be used but consideration needs
imperfection and thus achieving the desired finish without to be given to the width of the gasket, location of the gasket
reaction load, the effect of flange rotation, and surface finish
weld metal buildup.
on the ability of the gasket to seal.
305- 4.2 Repair by Welding 305-4.5.1 Considerations. Prior to converting
flange types, consideration shall be given to the impact of
In repairing a flange face, it may be necessary to use weld
such a change on the system design bases and
metal to either fill a local area (e.g., a gouge or a scratch] or
specifications, including such negative potential
to restore thickness by a weld buildup of the base metal or
consequences as sealing difficulties and gasket blowout.
existing weld overlay face. Where the flange is to be
The impact of the change with respect to system design
repaired by welding, the area where the buildup is to be
bases and specifications should be considered. Gasket
applied shall be free of any residue, gasket material,
materials for the new gasket type should be selected with
corrosion deposits, etc., that would unduly affect the weld.
due consideration for the service environment
Cleaning may be by mechanical or chemical procedures.
Welding procedures and personnel shall be qualified per 305-4.5.2 Materials. The material used for filling in
the requirements of an applicable new construction code the groove may match the base metal of the flange or may
(such as ASME BPVC, Section IX], or an applicable post- be a different material suitable for the process conditions.
construction code or standard. Where weld metal buildup For example, in some instances it may be desirable to fill in
is necessary; the filler metal, welding technique, welder a groove in a Cr-Mo flange using an austenitic stainless steel
qualifications, and heat treatment (if any] shall be selected filler. If the groove is filled with a material that has a
to meet service and metallurgical requirements. different coefficient of thermal expansion than the base
metal of the flange, consideration should be given to the
305- 4.3 Post weld Heat Treatment effects of differential thermal expansion. It is recognized
that some material may be removed from the bottom of the
When weld metal buildup is required, post weld heat
groove in order to prepare the surface for welding or to
treatment shall be performed prior to flange face machining
remove cracks or other flaws. If material other than the base
if required by an applicable new construction or post-
material is used to fill in the groove, this material removal
construction code. Post weld heat treatment is not required
can result in the flange thickness (see Figure
if the thickness of the weld metal buildup is less than the
limits prescribed in the applicable new or postconstruction
305- 4.5.2-1] composed of base metal being less than
code or standard unless dimensional stability is an issue, or
that specified by the applicable standard. This is acceptable
post weld heat treatment is required for process reasons.
if the depth of the weld does not exceed 10% of the flange
thickness. This 10% criterion may be increased if justified
by an engineering analysis. This analysis should be similar
to a Level 3 assessment in accordance with API 579-
1/ASME FFS-1.

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Section VIII, Division 1, Mandatory Appendices 6 and

8, respectively, or other applicable construction code,
e.g., ASME BPVC, Section VIII, Division 2.

305- 5.3 Dimensions

After repair, the flange thickness and other
dimensions shall be verified for conformance to the
required thickness of the applicable standard or as
established by design calculation.

305- 6 TESTING
After the flange joint is reassembled in the field, it
should be subjected to a leak test prior to being placed
in service, or an initial service leak test. An initial
service leak test is one in which the joint is monitored
for leakage as pressure is increased in the system. The
selection of the most appropriate testing method shall
consider the hazard of the service and any
305-4.5.3 Markings. If the ring joint flange that is being jurisdictional requirements. For general guidance on
converted is marked on its edge with the letter "R" and the flanged joint leak tightness testing, refer to Article 501
corresponding ring groove number (or other markings and ASME PCC-1, section 13.
identifying it as a ring joint), this marking shall be removed
or defaced (such as by stamping a series of X’s over it). 305- 7 REFERENCES

305- 5 EXAMINATION 305-7.1 Related Standards (18)

The following is a list of publications referenced in
305- 5.1 Gasket Surface this Article. Unless otherwise specified, the latest
The finished surface shall be examined to comply with edition shall apply.
the requirements of the standard applicable to new flanges
or as specified by the user. For example, ASME B16.5 API 660, Shell and Tube Exchangers for General
requires that the surface finish be judged by visual Refinery Service
comparison with the Ra standards of ASME B46.1. Publisher: American Petroleum Institute (API), 1220
L Street, NW, Washington, DC 20005
305- 5.2 Nondestructive Examination (www.api.org)
In cases where weld metal buildup is used in the repair, ASME B16.1, Cast Iron Pipe Flanges and Flanged
the area to be repaired shall be examined prior to Fittings ASME B16.5, Pipe Flanges and Flanged
performing the weld buildup using an appropriate NDE Fittings ASME B16.24, Bronze Pipe Flanges and
method to determine the integrity of the base metal. Flanged Fittings:
Consideration shall be given to examining each weld pass Class 150, 300, 400, 600, 900 and
for surface defects by either magnetic particle examination 1500 ASME B16.36, Orifice Flanges
(MT) or liquid penetrant examination (PT), as appropriate. ASME B16.47, Large Diameter Steel Flanges NPS 26
For example, such examination should be performed for Through NPS 60
welds susceptible to cracking. The finished machined Publisher: The American Society of Mechanical
surface shall also be examined by MT or PT, and Engineers (ASME), Two Park Avenue, New York,
imperfections in excess of the standard applicable to new NY 10016-5990 (www.asme.org)
flanges, or as specified by the user, shall be repaired and
reexamined by the method that discovered the Standards of Tubular Exchanger Manufacturers
imperfection. Guidelines for nondestructive examination Association
can be found in ASME BPVC, Section V. The MT or PT Publisher: Tubular Exchanger Manufacturers Association,
examination shall be conducted in accordance with ASME Inc. (TEMA), 25 North Broadway, Tarrytown, NY 10591
BPVC, (www.tema.org)

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Article 312
Inspection and Repair of Shell and Tube Heat Exchangers
312- 1 DESCRIPTION (c) current operating parameters, i.e., pressures,
This Article provides general good recommendations temperatures, changes from normal to peaking service.
(d) determination if a pressure and/or temperature
and requirements for the following repair techniques:
(a) determining the type of inspection technique
rerate is required.
(e) determination if there is a need for conducting
to use for the inspection of the tubes and tube
bundle of a shell and tube heat exchanger failure analysis to reduce the potential for future damage.
(b) determining the type of inspection technique
Reference also API 579/ASME FFS-1.
to use for the inspection of the tube sheet and 312- 3.2 General
the tube-to-tube- sheet assembly of a shell
and tube heat exchanger (a) Materials used for replacement components shall
(c) determining the type of inspection to use for be of the same material type as the original component
the other pressure containing components of unless an engineering analysis is performed indicating the
a shell and tube heat exchanger need to change the material due to the damage
(d) providing repair techniques for common mechanism(s). This analysis shall account for new
mechanical failures of various components in mechanisms introduced due to potential material
a heat exchanger interactions. When selecting the material to use, this
analysis shall also consider the need to match strength,
312- 2 LIMITATIONS toughness, and P-number, and to meet the current
toughness requirements of the applicable construction
312- 2.1 General code.
Part 1 of this Standard, "Scope, Organization, and (b) Replacement components shall be of equal or
Intent," contains additional requirements and limitations. greater thickness unless an engineering analysis is
This Article shall be used in conjunction with Part 1. performed indicating the need for a thickness less than
the original component thickness.
312- 2.2 Exclusions (c) When considering the repair method for tubes and
(a) This Article shall not be applied to heat exchangers tube bundles, the user shall consider the impact on the
constructed in accordance with ASME BPVC, Section VIII, efficiency and other operational characteristics of the heat
Division 3. exchanger due to the potential reduction of heat transfer
(b) Heat exchangers other than shell and tube design area. Consultation with a heat transfer specialist may be
are not included in the scope of this Article. necessary.
(d) The following additional factors should be
312- 3 DESIGN considered:
(1) Determination of acceptable wall loss will
This section provides guidelines for consideration
depend on a number of factors that include
when determining repairs to components of heat
(-a) duration of current service run
exchangers. It may be necessary for the user to have
(-b) time to the next planned outage
completed an inspection of the components, consider
(-c) the criticality of the exchanger operation
previous damage experienced, or consider lessons
(-d) damage mechanisms that the tubes are exposed to
learned in the operation of similar equipment prior to
including the rate of corrosion
beginning design work.
(-e) historical rate of failure and whether that rate has
312- 3.1 Existing Conditions been increasing
(-f) potential for metallurgical upgrade
Existing conditions are as follows: (-g) the potential consequence due to tube failure
(a) the original design conditions and calculations. (-h) equipment accessibility
(b) ensuring that the design conditions, with an (-i) the scope of the inspection work
appropriate margin, correspond to the actual normal (-j) the accuracy and effectiveness of the inspection
operating modes including startup, shutdown, and upset method
conditions.

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(2) For heat exchangers deemed critical to the and lead to tube vibration induced issues. If zero,
operation and/or process safety of the facility, the consideration should be given to assigning a nominal
following should also be considered: value of 3 mm (1/8 in.).
(-a) total replacement of the tube bundle when (2) Consideration should be given to use of alloy
tubes inspected indicate a wall loss of 40% or more of the support plates/baffles instead of thicker carbon steel;
initial, nominal thickness however, harder material may result in more damage to
(-b) tube bundle replacement or individual tube the tubes rather than the support plates/baffles. Also, the
replacement when tubes inspected indicate a wall loss of effects of differential thermal expansion should be
20% to 40% of the initial, nominal thickness considered. Consultation with a materials/ corrosions
specialist may also be necessary.
312- 3.3 Tubes and Tube Bundles
(3) The spacing between the support plates should
(a) Tubes and tube bundles should be assessed using be evaluated and adjusted if analysis indicates potential
the data obtained by inspection performed in accordance vibration of tubes resulting in damaged tubes and/or
with Mandatory Appendix 312-1 for the types of repairs support plates. Evaluation per TEMA RCB Section 5 and
to perform; plugging by welded, mechanical, or friction fit Section 6 should be considered. Consultation with a heat
plugs, partial replacement of the tube bundle, or full transfer specialist may also be necessary.
replacement of the tube bundle. (4) Tube stakes are rods, strips, or other devices
(b) When considering the use of mechanical or friction inserted between tubes for bracing and/or support. They
fit plugs, the user should consider the impact on the may be used to add tube support to an existing bundle for
efficiency and other operational characteristics of the the purpose of eliminating tube vibration. Installation
heat exchanger due to the reduction of heat transfer area, requires access from the shell side, and the main
especially for heat exchangers that are deemed as critical advantage is that disassembly of the tube bundle is not
to the operation and/or process safety of the facility. required. Special consideration may be necessary for the
Consultation with a heat transfer specialist may be use of stakes in U-tube bends because some stake designs
necessary. require that the tubes be round and evenly spaced.
(c) Sleeves may be installed in tubes to line a region of Tube stakes were developed for use when a change
tube damage or to restore tubes that have thinned. They in tube material or an increased flow rate requires
are not typically used for protection of tube ends; see additional tube supports, and increasing the number of
para. support plates is not possible or desirable. They can be
312- 4.4 and (d) below. used any time additional tube support is required such as
(d) Ferrules may be installed in tubes for entrance to provide additional support for deteriorated or
erosion protection of for thermal protection of tube ends. damaged support plates, to provide additional support
They are not typically used for general tube damage; see between segmented baffles, or to provide additional
para. 312-4.3 and (c) above. support at inlet nozzles. If tube stakes are fabricated from
(e) For (c) and (d), one should consider the following: flat bar and inserted in every other tube row, it may be
(1) uniformity of contact between the sleeve or necessary to vary the bar thickness such that each tube is
ferrule and tube, see paras. 312-4.3 (b) and 312-4.4 contacted or even displaced from its original position.
(2) possibility of crevice corrosion between the Evaluation of the shell-side pressure drop, and
sleeve or ferrule and tube changes in shell-side flow are necessary. The
(3) possibility of bulging the tube, which can make compatibility of tube and stake materials should be
retubing difficult evaluated. Also, the effects of differential thermal
(4) additional pressure drop expansion should be considered.
(g) If impingement protection is required to prevent
(5) reduction of tube fluid flow due to the sleeve or
flow-induced erosion, refer to applicable standards such
ferrule
as API Standard 660, TEMA, and HEI for design
(6) additional heat transfer resistance
requirements.
(7) differential radial and axial thermal expansion
between sleeve or ferrule and tube 312- 3.4 Tubesheet
(f) The tube bundle supports should be assessed
using the data obtained by inspection performed in (a) Material used to replace a tube sheet shall be of the
accordance with Mandatory Appendix 312-1. If data same or greater allowable stress as used for the original
indicates that failure of tubes is due to damaged support component
plates, consideration should be given to replacing with (b) If an engineering analysis indicates tube
alternative designs. Specific items to consider include the replacement of a larger diameter is required, additional
following: analysis on the tube sheet shall be performed to
(1) The corrosion allowance provided for the determine if the ligament efficiency is acceptable. The
support plate should be twice the value for the shell side analysis shall meet
due to the potential for the plates to corrode at the regions
where the tubes penetrate the supports

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the original construction code, or if this is not known, the (c) removing the tube and performing weld buildup of
analysis shall meet the requirements of ASME BPVC, Section the tube hole and then remachining the tube hole to the
VIII, Division 1. original tube hole diameter. Design of the mechanical joint
(c) Tube sheets should be assessed using the data should be made to the original construction code or
obtained by inspection performed by a method listed in applicable post-construction code, or to ASME BPVC,
Mandatory Appendix 312-11 for determination of repair or Section VIII, Division 1, Nonmandatory Appendix A. Caution
replacement of the tube sheet Common conditions for must be exercised to avoid damage to adjacent tubes.
consideration include (d) seal welding or strength welding of the joint. Design
(1) cracking (not through the total thickness] of tube of the welded joint, if previously welded, should be made to
sheet on shell side; more typical in vertical units. the original construction code or applicable
Installation of a tube sheet vent and drain should be postconstruction code, or to ASME BPVC, Section VIII,
considered to promote liquid full operation. The vent Division 1, Nonmandatory Appendix A. Consideration
should be a 19 mm (3/4 in.) nozzle welded to the edge of the should be given to the cleanliness of the joint considering
tube sheet, with a 16 mm (5/8in.) hole in the tube- sheet that potential residue from the fluids.
is parallel to the tubes to the midsection of the tube sheet, (e) consideration shall also be given to the effect of
then normal to the tubes to the edge of the tube sheet. A gate style of heat exchanger on loading of the tube-to-tube sheet
or ball valve should be installed on the nozzle along with a joint. For example, a fixed tube exchanger may have higher
blind flange or plug. loadings due to differential thermal expansion than a U-
(2) separation of weld overlay cladding resulting tube exchanger.
from wire drawing of high-pressure tube side fluid leaking
through tube-to-tube sheet joints.
312- 3.6 Bimetallic Shell-to-Tube sheet Welds
(3) cracking in the ligament of the tube sheet. A failure When the shell and tube sheet are made of different
analysis should be performed to determine the damage materials, the thermal stress between the shell and tube-
mechanism. The decision to repair versus replace the tube sheet should be considered. A common solution to cracking
sheet should be based on the damage mechanism along with of this weld is to change the shell material to match the tube
the extent of the ligament cracking. sheet An entire shell may be replaced, or bands or shell
(4) corrosion of the tube sheet can occur on the material may be installed adjacent to the tube sheet.
backside (shell side] of the tube sheet. When the corrosion Reevaluation of the heat exchanger mechanical design due
allowance on the backside has been consumed, the tube- to the change in thermal expansion or strength of the shell
sheet should either be replaced or an engineering may be required.
evaluation performed to determine its fitness for service. 312- 3.7 Shell, Channel, or Other Pressure-
(5) corrosion of the tube sheet can occur on the front Retaining Components
face (tube side] of the tube sheet When the corrosion
allowance on the face has been consumed, the tube sheet (a) Materials used to replace or repair pressure-
should either be replaced or an engineering evaluation retaining portions of a shell or channel shall be of the same
performed to determine its fitness for service. Alternatively, allowable stress as the original component, unless
the face of the tube sheet may be repaired by weld buildup additional analysis is performed to justify changing the
that is conditioned by grinding or other mechanical means material.
such that it is returned to the original thickness of the tube (b) Replacement of these or other pressure-retaining
sheet. Factors to consider when pursuing this option components shall comply with the applicable construction
include code. For additional guidance on replacement, see Article
(-a) minimum distance between the front face of 301.
the tube sheet and the groove for tube-to-tube sheet joints (c) Non-pressure-retaining portions of components
(-b) the need for welding, strength or seal, of the tube-to- shall meet the original construction code or applicable post-
tube sheet joint and the need for setback from the front construction code.
(d) Additional guidance on pass-partition plates may be
face
found in API Standard 660.
312- 3.5 Tube-to-Tube sheet Joints
Tube-to-tube sheet joints should be assessed using the 312- 4 FABRICATION
data obtained by inspection performed by one of the
methods listed in para. 312-5.3 for determination of repair
312- 4.1 General Considerations
type. Repair types for leaking joints include (a) When multiple heat exchangers are in use in a
(a) replacement of a damaged tube, see para. 312-4.6 parallel configuration, consideration should be given to the
(b) plugging a tube, see para. 312-4.2 flow requirements for each exchanger. Experience has
shown that a single heat exchanger removed from

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 ASME PCC-2-2018

(e) When it is known that a tube or multiple tubes are

leaking, consideration shall be given to pulling a tube for
failure analysis to aid in determination of the damage
mechanism.
(f) All welded repairs shall be made using qualified
welding procedures. Welders and welding operators shall
be qualified in accordance with the requirements of the
applicable construction code or post-construction code.
Welding procedure qualifications shall include impact tests
if required by the applicable construction code for the
component being repaired.
(g) Welding materials and processes shall be as
currently permitted by the applicable construction code or
post-construction code for the component. Welding of
carbon and low alloy steels should be performed with low
hydrogen electrodes and processes.
312- 4.2 Tube side Repair by Plugging
service can result in higher flows to the other heat Repair of tubes may be accomplished by plugging the
exchanger(s) that may cause damage from erosion, tube tube at the tube sheet with a welded or mechanical
bundle vibrations, or other mechanical damage. attachment
(b) Prior to repairs and to increase accuracy of (a) All tubes that are plugged should be pierced to
inspection, the tubes should be evaluated for the need to be provide for venting and draining. When doing so, vertical
cleaned. Cleaning may be performed by high pressure water tubes should be pierced at each end, and horizontal tubes
blasting, chemical solutions, or abrasive blasting/scrubbing. should be pierced on top and bottom of the tube. Piercing of
Selection of a cleaning methodology shall give consideration each tube prevents possible plug blowout and permits the
to the nature of fouling, tube material type, and tube validation of the integrity of the tube plug, see (b)(4).Large
enhancements. temperature differential between tube side and shell side
(1) High pressure water blasting is normally performed may require the tube to be cut in two.
at 70 MPa (10,000 psi). In some cases, ultra-high (b) Friction fit tapered plugs (Figure 312-4.2-1) shall
pressure water blasting may be necessary at only be used in services that meet all of the following
pressures up to 275 MPa (40,000 psi). Other factors conditions, unless an engineering evaluation is performed
essential to removal of deposits include water flow indicating the acceptability of these plugs in other services:
rate and the spray tip configuration. (1) shell-side operating pressure 1.5 MPa (200 psi] or
(2) When cleaning with chemical solutions, a materials less
engineer should be consulted to ensure no detrimental (2) shell-side operating temperature 205°C (400°F)
effects occur to the tubes and/or shell of the heat exchanger. or less
For example, a caustic solution should not be used in 300 (3) tube-to-tube sheet joints are expanded and not
series stainless steel tubes. welded
(3) When performing abrasive blasting/scrubbing,
NOTE: Inspection of the expanded tube for tube
care shall be exercised to ensure no adverse damage to the thinning should be made to ensure that installation of
tubes occurs. Deterioration of heat transfer capability shall the plug does not further damage the tube leading to
be considered when cleaning tubes with internal seal failure between the plug and the tubes.
components designed to enhance heat transfer by increasing (4) tapered plugs that are installed where tubes are
turbulence through the tubes. not pierced can present a serious safety hazard. If the tube
(c) Inspection of the tubes periodically during the cannot be pierced, the tube should be pulled or other
cleaning process should be made to ensure consistent measures should be taken to ensure personnel protection,
results. Use of a horoscope may improve inspection results. such as welding the plug to the tube sheet and draining all
(d) When a tube bundle must be removed from its shell liquids from the tube being plugged.
for purposes of inspection or repair, caution should be Mechanical plugs (Figure 312-4.2-2] should be considered
exercised to avoid damage to the tubes or other in situations where friction fit tapered plugs are not
components. appropriate for the pressure and/or temperature of service
or other mechanical/environ- mental conditions. These
types of plugs have been used in services of up to 50 MPa
(7,000 psi) and

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595°C (1,100°F). Mechanical plugs are typically installed by a (c) A plug map should be developed to record the
pneumatic or hydraulic system. See Figure 312-4.2-3. Other number and location of tubes that have been plugged.
styles of plugs may be considered for higher pressures. Additionally, the number of tubes, cumulative number of
Consideration shall also be given to the following: tubes versus the duration, should be charted. When the
(1) tubes with internal surface severely corroded or sharp turn in tube failure numbers occurs, replacement of
cracked the tube bundle should be considered. See Figure 312-4.2-4
(2) when the tube and the plug have dissimilar for example chart.
metallurgy (d) Tracking of pressure loss due to tube luggage should
(3) installation in severely corrosive service be considered as some exchanger types cannot function
(4) condition of the mechanical joint of the tube-to- properly beyond certain tube side pressure losses.
tube sheet in rolled tube situations Provisions for internal bypass should be considered if
repair is not performed in order to prevent failure of pass
partitions. Proper design of this bypass can be determined
from industry references in section 312-7 of this Article.
312- 4.3 Tube side Repair by Sleeving Tubes
(a) Sleeving versus tube replacement may be
advantageous when repairing previously plugged tubes
because of perforations in discreet identifiable locations, or
to bridge failures in discreet locations of tubes that are
otherwise intact
(b) The methods of sleeve installation include the
following: forcing a ball though the sleeve, welding the ends
of the sleeve, roller expansion of the sleeve, explosive
bonding of the sleeve and hydraulic expansion of the sleeve.
One should consider the possibility of bulging the tube,
which can make retubing difficult. A mock-up may be
advisable to ensure weld or expansion quality.
A map should be developed to record the number and
location of tubes that have been sleeved. Additionally, the
number of tubes, cumulative number of tubes versus the
service time should be charted. If a sharp increase in tube
failures occurs, replacement of the tube bundle

GENERAL NOTE: ©2006 Photo courtesy of EST Group Inc.,

used with permission.

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 ASME PCC-2-2018

should be considered. See Figure 312-4.2-4 for example 312- 4.7 Tube sheet Repair
chart. 312- 4.7.1 Weld Repair of Cracks
312- 4.4 Tube side Repair by Ferrule (a) Repair of general cracks that are not completely
Installation through the thickness of the tube sheet and are not in the
ligaments may be made in accordance with the guidelines
Ferrules may be held in place by a flanged end with a
of Article 304.
tight fit to the tube inside diameter, by expanding the ends
(b) Repair of general cracks that are through the
of the ferrule into the tube at the tube sheet, or by welding.
thickness of the tube sheet and not in the ligaments may be
Uniform contact with the tube may be achieved by roller or
repaired by preparing a U- or V-shaped groove to the full
hydraulic expansion of the ferrule. One should consider the
depth and length of the crack and then filling the groove
possibility of bulging the tube, which can make retubing
with weld metal in accordance with paras. 312-
difficult. A mock-up may be advisable to ensure weld or 4.7.1 and 312-4.7.2.
expansion quality. (c] Repair of cracks in the ligament area of the tube-
312- 4.5 Tube side Repair by Pulling Tubes sheet may be made in accordance with (a) or (b) above.
Consideration may also be given to performing an
(a) Pulling the tube from the exchanger and plugging the
engineering analysis to determine if the equipment may
tube sheet as described in para. 312-4.2 should be
continue to operate with the damaged tube sheet. This
considered as a repair option when plugging is not a viable
analysis may be performed in accordance with API 579-
alternative, or when the tube will be retained for laboratory
1/ASME FFS-1 or other post-construction standard.
metallurgical analysis or other specific examination.
(c) When making tube sheet repairs, consideration
(b) When pulling a tube and not replacing, potential
should be given to the impact of this repair on the tubes in
damage to the baffle could occur and consideration to
the general area of the repair. The following actions may be
replacing the tube should be made. Consultation with a heat
necessary:
transfer specialist may also be necessary.
(1) removal of tubes in the general area of the repair.
312- 4.6 Tube side Repair by Replacement See para. 312-4.5 (b).
Repair may be performed by tube replacement, which (2) repair of the tube-to-tube sheet joints.
may be accomplished in one of the following methods: 312- 4.7.2 Face Repair by Overlay and
(a) replacing individual tubes, which may include Machining
repair/refurbishing of the tube sheet in the area of the (a) General and localized thinning of tube sheets may be
subject tube. repaired by overlay welding and remachining of the face.
(b) replacement of the entire tube bundle. See para. 312- (b) See Article 202 for additional items of
3.2(c). consideration.

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312-4,8 Tube-to-Tube sheet Joint Repair required by the applicable construction code for the
tube sheet
312-4.8.1 Re-Expanding (d) Welding materials and processes shall be as
(a) Cleaning and inspection shall be performed to currently permitted by the applicable construction code or
determine the condition of the tube-to-tube sheet joint post-construction code for the tube sheet. Welding of
prior to performing this type of repair. See para. 312-4.1. carbon and low alloy steels should be performed with low
(b) Tube-to-tube sheet joints with leaks of a small flow hydrogen electrodes and processes.
rate, otherwise known as weeping tubes, where no
apparent damage has occurred to the seating surfaces, 312-4.9 Repair of Pressure Containment
may be re-expanded to obtain an acceptable mechanical Components
fit of tube to tube sheet Rerolling is one acceptable
method of re-expanding. Repairs to the heat exchanger shell may be performed
(c) Prior to re-expanding, the existing inside to the original construction code or applicable
diameter of the tube in the tube sheet shall be determined postconstruction code. See also Article 201 and Article 202.
as well as the loss of material due to corrosion/erosion.
312-5 EXAMINATION
Calculations for allowable maximum inside diameter shall
be based on measured field conditions, tube properties, Examination of heat exchangers typically covers three
and tube sheet ligament condition. areas; external, internal, and tube bundle. It is not necessary
(d) See ASME BPVC, Section VIII, Division 1, for each inspection to have the same frequency.
Nonmandatory Appendix HH for additional 312-5.1 Examination of Tubes and Tube Bundle
considerations.
It is important for the proper examination technique to
312-4.8.2 Weld Buildup Repair of Tube Holes be selected for the application at hand. The following
and Machining nondestructive examination (NDE] techniques should be
(a) When a tube is replaced and the tube hole has been considered for the given application. See also Table 312-1-
damaged, repair may be effected by weld buildup and 1.3-1 for effectiveness of examination methods. Other
machining of the hole. examination methods may be chosen by the
(b) All welded tube hole repairs shall be made using owner/operator, as follows:
qualified welding procedures. Welders and welding (a) Eddy Current Examination (ET] is generally selected
operators shall be qualified in accordance with the for inspection of nonferromagnetic tubes, or those that are
requirements of the applicable construction code or post- slightly magnetic. Note that the sensitivity of this method
construction code. Welding procedure qualifications shall decreases for the U-bend portion of U-tube bundles.
include impact tests if required by the applicable (b) Remote Field Eddy Current (RFET] is generally
construction code for the tube sheet used for inspection of ferromagnetic tubes. Its sensitivity
(c) Welding materials and processes shall be as and accuracy may be less than desired or required and will
currently permitted by the applicable construction code require a higher number of tubes to be inspected. It is a
or post-construction code for the tube sheet. Welding of quicker method than ultrasonic methods.
carbon and low alloy steels should be performed with low (c) Partial Saturation Eddy Current (PSET) can locate
hydrogen electrodes and processes. and size cracks in ferromagnetic tubes. It might not be
(d) Machining of the hole shall be to original sensitive to O.D. defects.
manufacturer's specifications for diameter and grooving. (d) Magnetic Flux Leakage (MFL) may also be selected
for inspection of ferromagnetic tubes. However, sensitivity
312-4.8.3 Seal Welding or Strength Welding of this method can be poor for carbon steel tubes, and might
(a) Tube-to-tube sheet welds shall be in accordance only be best at determining the overall condition of the tube,
with the applicable construction code or post- not determining individual defect location.
construction code. (e) Ultrasonic examination systems designed to
(b) If seal welds are to be made, consideration shall be measure tube wall thickness may be used for small heat
given to the mechanical tube-to-tube sheet joint to ensure exchangers, where damage may be localized, or for
its strength. If seal welds are determined to be validation of other NDE results. These ultrasonic
inadequate, the weld shall be full strength to ensure the examination systems are particularly suited for carbon steel
integrity of the joint. tubes due to the lack of sensitivity of other NDE methods.
(c) All welds shall be made using qualified welding One type of system is the Internal Rotary Ultrasonic
procedures. Welders and welding operators shall be Inspection (IRIS) system. IRIS is an accurate NDE method
qualified in accordance with the requirements of the for detecting and sizing I.D. and O.D.
applicable construction code or post-construction code.
Welding procedure qualifications shall include impact
tests as

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metal loss in tubes. Another type of system is Shear API 579-1/ASME FFS-1, Fitness-For-Service, 2nd Edition,
Wave IRIS (SWIRIS) and this can be effective for 2007
detecting I.D. and O.D. cracks. Both IRIS and SWIRIS API Standard 660, Shell and Tube Heat Exchangers for General
require clean tubes. Refinery Services, 2003 Edition
(f) Other NDE methods may be more appropriate Publisher: American Petroleum Institute (API), 1220 L Street,
for the inspection. Consideration should be given to NW, Washington, DC 20005 (www.api.org)
the use of radiography (RT) or video probe inspection. ASME Boiler and Pressure Vessel Code, 2007 Edition, Section
These methods may be better suited for inspection of V — Nondestructive Examination
the U- bend portion of U-tube bundles. ASME Boiler and Pressure Vessel Code, 2007 Edition, Section
(g) Consideration should be given to the VIII, Division 1 — Rules for Construction of Pressure
monitoring and trending of tube condition as part of a Vessels
predictive maintenance and/or replacement program. ASME PCC-3, Inspection Planning Using Risk Based Methods
(h) The minimum number of tubes to be inspected Publisher: The American Society of Mechanical Engineers
may be determined by the methods provided in (ASME), Two Park Avenue, New York, NY 10016-5990
Mandatory Appendix 312-1. (www.asme.org)
312-5.2 Examination of Tube-to-Tube ASTM E2283-03, Standard Practice for Extreme Value
sheet Repair Analysis of Nonmetallic Inclusions in Steel and Other
Microstructural Features
Repairs shall be examined by one or more of the
Publisher: American Society for Testing and Materials (ASTM
following methods:
International], 100 Barr Harbor Drive, P.O. Box C700, West
(a) pressure or leak testing on the shell side; see
Conshohocken, PA 19428-2959 (www.astm.org)
section 312-6
(b) liquid penetrant examination (PT) in Wolf, Gerald M. and Adams, Robert B., An Improved P l ug g i n g
accordance with the applicable construction code or S y s t e m f o r HX T ub i n g , E P R I B P O Conference paper
post-construction code , June 1996
(c) visual examination (VT) in accordance with Publisher: Electric Power Research Institute (EPRI), 3420
ASME BPVC, Section V, Article 9 Hillview Avenue, Palo Alto, CA 94304 (www.epri.com)

312-5.3 Examination of Tube sheet Repair Standards for Power Plant Heat Exchangers, 4th Edition, 2004
Standards for Closed Feedwater Heater, 7th Edition, 2004
(a) VT in-process weld examination shall be
Publisher: Heat Exchange Institute, Inc. (HEI), 1300 S umme r
performed. A v e n ue , Cleveland, OH 44115
(b) Surface examination by PT shall be performed
(www.heatexchange.org)
at the completion of the weld repair.
(c) Volumetric examination by UT should be Standards of the Tubular Exchanger Manufacturers
considered when there is a possibility of additional Association, 8th Edition
flaws being introduced to the tube sheet during the Publisher: Tubular Exchanger Manufacturers Association, Inc.
repair. (TEMA), 25 North Broadway,Tarrytown, NY 10591
(www.tema.org)
312-5.4 Examination of Pressure
Andreone, Carl F. and Yokell, S., Tubular Heat Exchanger
Containment Components Repairs
Inspection, Maintenance and Repair, McGraw-Hill, New
(a) All welded repairs should receive VT and PT or York, 1997
MT examination, especially for heat exchangers Wang, W. David, Ph.D., "Extreme Value Analysis of Heat
deemed critical to the operation and/or process safety Exchanger Tube Inspection Data," Proceedings of
of the facility. PVP2006-ICPVT-11, 2006, ASME Pressure Vessels and
(b) Where possible, welded repairs shall receive Piping Division Conference July 2006
volumetric examination by RT or UT. Bypass-calculation-R3.xls (http://www.mgt-inc.com/
docs/Bypass-calculation-R3.xls)
312-6 TESTING
Following completion of the inspection, a pressure
test or tightness test in accordance with Article 501
should be considered, particularly if the integrity of
the tube-to- tubesheet joint is in question.

(18) 312-7 REFERENCES

The following is a list of publications referenced in
this Article. Unless otherwise specified, the latest
edition shall apply.

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Mandatory Appendix 312-I

Methods for Determining Minimum Number of Tubes to Inspect

312-I-1 Introduction 312-I-1.3 Use of Inspection Planning

This Mandatory Appendix provides general good (a) An inspection planning program may be
recommendations and requirements for determining the implemented to determine the number of tubes to
number of tubes to inspect by different methods. The user inspect and the frequency at which the tubes shall be
may select any method, and may also deviate from the inspected.
recommendations and requirements of each method (b) Program implementation guidelines are provided
based on the requirements of the heat exchanger. in ASME PCC-3. The following factors s ho u l d b e
considered:
312-1-1.1 Fixed Tube Count
(1) inspection effectiveness required, see Table
The following minimum number of tubes inspected 312- (-1.3-1 for various effectiveness and the associated
should be considered: methods of inspection.
(a) 50 tubes or 25% of tube total, whichever is greater, (2) maximum inspection interval permitted.
for heat exchangers with a total tube count of less than (3) type of inspection required for the suspected
500 tubes damage mechanism. See Table 312-1-1.3-1 for additional
(b) 20% of tube total for heat exchangers with a total details.
tube count of 500 tubes or more, up to 750 tubes
(c) 15% of tube total for heat exchangers with a total (c) See para. 312-5.1 for inspection methods.
tube count of 750 tubes or more, up to 1,000 tubes
(d) 10% of tube total for heat exchangers with a total 312-I-1.4 Use of Extreme Value Analysis (EVA)
tube count of more than 1,000 tubes (a) Use of EVA makes it possible to accurately assess
the remaining life of large numbers of tubes using
312-1-1.2 Tube Bundle
relatively minimal data.
The following areas of the tube bundle should be (b) EVA assessment is based on ASTM E 2283,
examined at a minimum: “Standard Practice for Extreme Value Analysis of
(a) the first three rows adjacent to the inlet nozzle and N o n me t a l l i c I n c l u s i o n s i n S t e e l a n d O t he r
the last two rows adjacent to the exit nozzle. Microstructural Features."
(b) every second tube around the perimeter of the (c) Use of EVA to assess the maximum wall loss data
bundle. For multipass heat exchangers, the perimeter of has been described in conference publications; see Table
each pass shall be included. 312- I-1.3-1, Note (4).
(c) a selection of tubes in the interior section of the (d) The EVA method and results may be incorporated
bundle. into an inspection planning assessment
(d) areas with a history of active damage mechanisms. (e) With smaller sample sizes, ideally 20 to 30 tubes
(e) areas that have not previously been examined. regardless of the number of tubes in the exchanger, the
(f) failure of 10% of the tubes examined shall require appropriate inspection effectiveness may be achieved by
an additional 10% of tubes to be examined in the using the lower bound value of 99%, 95%, 90%, and 80%
examined area, as per (a) through (e). confidence intervals.

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Table 312-1-1.3-1 Inspection Effectiveness Table (Cont'd)

GENERAL NOTE:
ET = eddy current testing
EVA = extreme value analysis
IRIS = internal rotary inspection system
MFL = magnetic flux leakage
MIC = microbiologically induced corrosion
RFET = remote field eddy current
PSET = partial saturation eddy current
SWIRIS = shear wave internal rotary inspection system

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Mandatory Appendix 312-II Examination of Pressure

Containment Components
312-II-1 EXAMINATION 312-II-2 INSPECTION
Examination of the shell, channel, and other pressure The inspection of these components should occur
containment components, excluding the tubes, may be concurrently with the inspection of the tubes.
performed by any of the following methods:
(a) RT 312-II-3 SUITABILITY
(b) UT
Pressure containment components are particularly
(c) MT
suited for inspection planning methods such as described
(d) VT
by ASME PCC-3.
(e) internal inspection by removal of tube bundle
(f) internal inspection by remote camera or other
inspection probe instrument

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PART 5
EXAMINATION AND TESTING
Article 501
Pressure and Tightness Testing of Piping and Equipment
(18) 501-1 DESCRIPTION
501-3 DESIGN
(a) This Article provides general good practice for
determining the type of test, the test pressure, and the 501-3.1 Definitions
procedure for pressure and tightness testing of closure weld: the final weld connecting piping
pressure equipment, including tubular heat systems or components that have been successfully
exchangers, pressure vessels, and piping systems. This pressure tested in accordance with the applicable
Article is intended for use when construction code.
(1) a complete vessel or system is to be pressure tested
hydrostatic test: a pressure or tightness test where
(2) a pressure vessel or system is isolated such that
liquid, typically water, is the test medium.
pressure testing is completed on a portion of the
in-service leak test: a test using the process
pressure vessel or system. For selection of test
medium of the pressure equipment performed at start-
devices for localized pressure testing of welded
up of the equipment
repairs of piping systems, see Article 503.
pneumatic test: a pressure or tightness test where a
(b) General information regarding the various types of
gas, generally nitrogen or air, is the test medium.
tests to choose from is provided, including
pressure test: a test performed to ensure the gross
application, benefits, and limitations.
(c) Refer to individual repair articles of this Standard
integrity of the pressure component on new pressure
for any pressure or leak testing requirements or equipment, or on previously manufactured pressure
recommendations that should be followed. and piping equipment that has been or is in service and
has undergone an alteration or repair to its pressure
(18) 501-2 LIMITATIONS boundary(ies) to ensure the gross integrity of the
pressure component to the original construction code.
(a) Part 1 of this Standard contains additional
A pressure test may be performed with liquid
requirements and limitations. This Article shall be
(hydrostatic test), gas (pneumatic test), or a
used in conjunction with Part 1.
combination of both (hydropneumatic test).
(b) This Article shall be limited to use for field pressure
tightness test: a test that is performed to ensure
or tightness testing of existing equipment and overall leak tightness of the system or its connections
piping using either of the two fluid mediums, liquid before the process medium is introduced.
or gas.
(c) This Article shall not be used for vacuum testing of 501-3.2 Reasons for Pressure and Tightness (18)
equipment or piping. Testing
(d) This Article addresses pneumatic testing. (a) The primary purpose of performing a pressure
Pneumatic testing is potentially much more test is to verify the integrity of a pressure system. This
hazardous than hydrostatic testing due to the is especially true when welded repairs or alterations
higher levels of potential energy in the have been performed on the pressure boundary.
pressurized system; therefore, all . reasonable Pressure and tightness testing are not substitutes for
alternatives shall be considered before this option proof testing a design.
is selected. (b) Pressure or tightness tests can be used to check
for pressure system leakage, especially in flanged
joints. Tightness tests may be performed in
conjunction with the pressure test

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(c) Hydrostatic pressure testing can provide some the completion of the pressure test, the tubes should
mechanical stress relieving. This is accomplished when local be inspected for buckling that may have occurred.
regions of high stress, such as at stress concentrations and
crack-like imperfections, undergo local yielding during the 501-3.4.1 Exclusions From Hydrostatic
pressure test. Release of pressure then produces Test.
compressive residual stress in these regions, such that when Pressure testing should be performed hydrostatically
pressure is reapplied, the operating stress is less than would unless one of the following conditions apply:
have occurred otherwise. This can help mitigate the risk of (a) The equipment, piping, and/or supports, including
brittle fracture when it is a consideration. Subsequent foundations, cannot adequately support the liquid weight.
operation, especially at elevated temperatures, can reduce (b) The equipment or piping cannot be dried and
or eliminate any stress-relief benefit or brittle fracture traces of the test liquid may result in contamination of
control. Hydrostatic pressure testing does not eliminate the the system or its contents after returning to service.
need for post weld heat treatment, whether required by the (c) The equipment or piping contains internal linings
applicable construction code or by the user’s requirements. that could be damaged by the test medium.
See also para. 502-1.7. 501-3.4.2 Pneumatic Test Conditions.
(d) The use of a device to isolate and test a weld If a hydrostatic test cannot be performed per para.
independently of the complete pressure vessel or system 501-3.4.1, then a pneumatic pressure test should be
may be considered when pressure testing at a full test considered.
pressure in accordance with section 501-6 is required (see (a) If a pneumatic pressure test would present
para. 501-3.3). It should be noted that use of devices to unacceptable hazards, such as risk of brittle fracture at
isolate and test a weld should be used in conjunction with the metal test temperature, then a substitute for
activity-appropriate welding controls, in-process weld pressure testing should be developed.
examinations, and NDE (see Article 502). For selection of (b) See para. 501-6.2(d) for information regarding the
test devices for localized pressure testing of welded repairs need for risk analysis.
of piping systems, see Article 503.
(e) Tightness testing may be considered when structural 501-3.4.3 Localized Pressure Testing
integrity does not need to be verified but leak tightness must Considerations (18)
be verified prior to start-up. (a) Use of a test device for localized pressure
(f) In-service leak testing can be considered when testing may be considered when any of the following
structural integrity does not need to be verified and the conditions exist:
consequences of a leak during start-up are acceptable, or (1) Other welds in the system under
when permitted by the applicable construction code or post- consideration have already been tested or are exempt
construction code. from testing.
(2) Brittle fracture may be a consideration.
501-3.3 Test Type Selection (3) There is a need to minimize the number of
The requirement for pressure testing can be found in the flanged joints to disassemble for the purpose of
applicable construction code or post-construction code. installing isolation blind flanges.
When no test is specifically referenced, Figure 501-3.3-1 (4) There is a need to minimize the amount of
shall be used to determine the type of test to be performed. test fluid and/or avoid contamination of process items
501-3.4 Pressure Test — General in the system, such as catalyst, linings, refractory, or
other process equipment
(a) A pressure test of equipment or a piping system
(5) Complete isolation is not possible or
should be considered if an alteration or repair has been
practicable, such as when a piping system is welded
performed, the equipment has been rerated, or it needs to be
directly to the nozzle of a pressure vessel.
recertified to determine integrity. (6) Sole use of radiographic testing (RT) or
(b) A pressure test may not be required for rerating other volumetric examination is not desired or
equipment using a higher allowable stress since the original practicable.
pressure test could be higher than the test pressure required (7) There is a need to minimize the amount of
for rerating. insulation abatement and reinstallation.
(c) Pressure testing [or alternatively, tightness testing; (8) There are potential consequences or
see para. 501-6.3(a)] should be considered during routine additional risks associated with test fluid remaining in
inspections and after cleaning operations when the integrity the system following completion of a pressure test.
of tube-to-tube sheet joints is in question. Following (9) There is a need to minimize disassembly
and/or removal of system components.
(10) A repair versus an alteration has been
performed. (See Article 502 for information on repair
and alteration.)
(b) Test devices for localized pressure testing shall be
selected and installed in accordance with Article 503.

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501- 3.4.4 Nondestructive Examination (b) In order to reduce the risk of brittle fracture during
Considerations. Nondestructive examination may be the test, the temperature of the metal during the pressure
considered in lieu of pressure testing to verify repairs or test of pressure vessels should be maintained at a minimum
alterations in some instances (see Article 502). This may of 17°C (30°F) above the minimum design metal
require the use of tightness testing as well. temperature (MDMT) (as shown on the Manufacturer’s Data
Report).
501-3.5 Documentation (1) If the MDMT is unknown, the minimum allowable
temperature (MAT) of the component or system should be
A pressure test record form should be prepared determined using a fitness-for-service evaluation.
prior to the pressure test and completed upon (2) If a vessel made of low-alloy steel has been
acceptance of the test by the owner or the owner’s subjected to thermal treatment or service temperatures over
designated representative. A sample record form is 370°C (700°F), an upward shift in the ductile-to- brittle
provided in Mandatory Appendix 501-1. transition temperature may have occurred. This loss of
toughness may not be readily apparent during operation;
501-4 FABRICATION
however, the vessel may be susceptible to brittle fracture.
Within the context of this Article, this section is not Therefore, the temperature used for the pressure test may
applicable. need to be determined by a fitness-for-service evaluation.
(c) When pressure testing piping systems, the ambient
501-5 EXAMINATION temperature should be greater than 2°C (35°F). When
Visual examination shall be performed during the pressure testing at colder temperatures, the use of an
pressure, tightness, or in-service leak test to antifreeze solution should be considered as the test medium
determine if any leakage is occurring during the test to prevent freezing; however, the metal temperature should
When visual examination is not possible, e.g., with be kept above the ductile-brittle transition temperature.
underground piping, monitoring of system pressure Additional guidance regarding pressure testing at cold
for pressure drop during tightness or in-service leak temperatures may be found in the references listed in
test may be substituted when approved by the owner. section 501-7.
See paras. 501-6.1(t)(8) and 501-6.2.1, Step 3(c) (d) The vessel and its supports and the foundation
regarding safety practices. - . and/ or the piping system and its supports and support
structures should be evaluated to determine if they will
501-6 TESTING adequately support the weight of the test medium.
(e) Pressure gauges used for recording test pressures
(18) 501-6.1 Hydrostatic Pressure Test of should be calibrated and located at the highest point on the
Pressure Vessels or Piping Systems vessel or on the piping system. The gauges should meet the
(a) The fabrication and in-service inspection requirements of ASME PTC 19.2 or similar gauge
records along with any necessary operational records performance standard, and be corrected as required to
should be reviewed prior to testing to determine if the compensate for the static head present in the system.
pressure component/system has experienced a (f) Vents shall be provided at the high points of the
credible damage mechanism. Consideration should be vessel and/or piping system to purge air from the tested
given to how each mechanism could manifest itself component while it is being filled.
during a pressure test See section 501-7 for references (g) The vessel or piping system shall be evaluated for
that provide considerations for damage mechanisms. components that will not withstand the test pressure or will
(1) The inspection records should be reviewed otherwise interfere with a pressure test. Examples of these
for thinning beyond the specified limit. If thinning has components include orifice plates, flow nozzles, control
occurred beyond the specified corrosion allowance, an valves, expansion joints, etc.
engineering evaluation shall be performed using (h) An evaluation for the need of overpressure relief
current inspection data. devices shall be performed. The set pressure of a pressure
(2) The material may have been subjected to relief device should be no more than the lesser of:
damage due to temperature or process exposure. If (1) the test pressure plus 345 kPa (50 psi), or
evidence of damage is found by inspection, an (2) 110% of the test pressure
engineering evaluation shall be performed using (i) Consideration shall be given to proper disposal of
current inspection data. the test water, as it may contain residual traces of the system
(3) The component/system may have been contents.
damaged by mechanical means such as high vibration.
Consideration should be given to analyzing the system
for areas where damage could occur and then
inspecting these areas prior to testing to look for
evidence of damage.

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(j) Pressure testing should be completed prior to Sat/Sdt = ratio of allowable stresses; the lowest
insulating. Welds or other joints that have previously been value shall be used in eq. (1) for all
pressure tested can be insulated or otherwise covered materials considered
when agreed to by the owner-user.
(k) Pressure testing should be completed prior to (2) A pressure equal to that which results in an
painting weld joints, unless the weld joints were applied general primary membrane tensile stress
previously tested. Documented test results indicate equal to 90% the specified minimum yield stress at
various types of paint will retain pressure during a test temperature of carbon steel material, or 100% of
pressure test when covering a through-wall "pinhole." austenitic steel material. Values for yield strengths for
When deciding whether or not welds may be painted prior some materials are provided in ASME BPVC, Section II,
to pressure testing, the following should be given Part D.
consideration: (o) The test pressure for a hydrostatic pressure
(1) the paint system(s) being used and its ability to test for piping systems should be specified by the
mask a potential leak owner and should be according to the original
(2) the probability that the process fluid(s) will act construction code,
as a solvent on the paint system if a pinhole is present, (p) When the requirements of the original
thus increasing the potential for a leak to occur construction code are not available, the test pressure
(3) the effect on nearby equipment or personnel if a for a hydrostatic pressure test for piping systems
leak occurs should be specified by the owner and should be at least
(4) the cost of performing repairs in the field if such
a failure occurs
(l) It is not required for the inspector approving the
hydrostatic pressure test to be certified per SNT-TC-1A for where
Leak Testing or Visual Examination; however, the 1.5 = test factor
inspector should have the authority to stop a pressure test P = internal design pressure of the piping system P t =
when deemed necessary to do so. Dedicated lines of test pressure to be used, measured at the highest
communication should be in place between the inspector point of the piping system in its normal operating
having oversight authority and all other personnel position
performing the pressure test. Sat = allowable stress attest temperature from the
(m) The test pressure of a hydrostatic pressure test applicable construction code for the material of
of pressure vessels or heat exchangers should be which the component under consideration is
according to the original construction code, considering constructed
also any subsequent engineering analysis as deemed S dt = allowable stress at design temperature from the
necessary. applicable construction code for the material of
(n) When the requirements of the original which the component under consideration is
construction code are not available, the test pressure for a constructed
hydrostatic pressure test for pressure vessels or heat Sat/Sdt = ratio of allowable stresses; the lowest value
exchangers shall be the lesser of (1) or (2) below. shall be used in eq. (2) for all materials
(1) Equation (1) considered

The resulting stress due to test pressure, P t , shall be

limited to 100% of yield strength, Sg.
(q) If the design pressure of the piping system
where cannot be verified, the value for Pin eq. (2) may be the
1.3 = test factor lesser of (1) or (2) below normalized to the highest
P = maximum allowable working pressure from the point of the piping system.
Manufacturer's Data Report, or the value to (1) The working pressure at design temperature
which the vessel is being rerated for flanges in the piping system from ASME B16.5 or
P t = test pressure to be used, measured at the top of the other applicable standard.
vessel in its normal operating position (2) The maximum allowable pressure calculated
S a t = allowable stress at test temperature from the for the limiting component of the piping system.
applicable construction code for the material of (3) The test pressure should not exceed that
which the component under consideration is which results in an applied general primary membrane
constructed tensile stress greater than 100% the specified
S dc = allowable stress at design temperature from the minimum yield stress at test temperature. Yield
applicable construction code for the material of strengths at ambient temperature may be found in
which the component under consideration is ASME B31.3 or other applicable construction code.
constructed Yield strengths at higher

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temperatures may be found in ASME BPVC, Section II, Part (-b) If further drying is necessary, the use of
D. hot air or hot nitrogen should be considered.
(r) Pressure testing of a piping system through (-c) If complete drainage of austenitic stainless
equipment is not recommended. Piping may be tested with a steel vessels and/or piping systems is not possible, the
pressure vessel if it is impractical to isolate the piping from components should be flushed with low-chloride (less
the vessel, the test pressure of the piping is equal to or less than 5 ppm) water.
than the test pressure of the vessel and the vessel and its (10) After completion of the test, the vessel
supports will adequately support the weight of the test and/or piping system should be restored to its
liquid. operating condition. This includes, but is not limited to,
If the test pressure of the piping exceeds the test pressure (-a) through (-f) below.
of the vessel, the vessel test pressure can be used, provided (-a) All flanged joints blinded for pressure
it is at least 77% of the piping test pressure; otherwise the testing should be reassembled with new gaskets and
piping should be isolated from the pressure vessel and tightened in accordance with applicable specifications.
pressure tested independently. Consideration should be given to ASME PCC-1.
(s) Piping systems that operate at atmospheric pressure (-b) All strainers contained in the piping
may be leak tested by filling with test liquid only. system should be removed, cleaned, and reinstalled.
(t) The items specified in (1) through (9) below should (-c) Temporary travel stops installed in spring
be considered when developing hydrostatic pressure test supports should be removed.
procedures for vessels or piping systems. (-d) Vent and bleed connections that were
(1) All equipment and/or piping to be tested should be installed for testing purposes only should be plugged
verified as being clean of dirt, weld slag, construction debris, using materials and methods per the applicable
or other unacceptable foreign matter. specification. Consideration should be given to seal
(2) Items identified in (g) should be removed. welding when necessary.
(3) All spring supports in vapor service lines should be (-e) Relief or safety valves that were isolated
protected with adequate travel stops to prevent overloading for the test shall have the isolating devices (e.g., gags,
during the pressure test slip blinds, etc.) removed.
(4) Temporary supports should be provided for piping (-f) Expansion joints that were locked to
and/or piping supports that have not been designed to prevent damage during the pressure test shall be
support the weight of the test liquid used for hydrostatic unlocked.
pressure test
(5) The use of salt or brackish water should be 501-6.2 Pneumatic Pressure Test of Pressure (18)
avoided. Test water should be free from sediment and Vessels or Piping
corrosive substances. (a) When a hydrostatic pressure test cannot be
(6) The test water should be verified to be free of performed per para. 501-5.1 (see para. 501-3.4.1), a
microbes. If the water contains an unacceptable level of pneumatic pressure test may be performed.
microbes, it should be disinfected. (b) Nitrogen should be the test medium since it
(7) Test water used for austenitic steel vessels or
cannot support combustion. Alternatively, clean, dry,
piping systems, or for components clad or overlaid with oil-free air meeting the requirements of Class 1, 2, or 3
austenitic stainless steel, should be condensate, air per ISO 8573-1:2010 should be used with a dew
demineralized, or of potable quality, with a verified chloride point ranging from -20°C to -70°C (-4°F to -94°F).
content of less than 50 ppm. Caution should be used when introducing air into any
(8) Following a hold-time of a minimum of 10 min, the
system that cannot be verified as being free of
pressure should be reduced by 30%, or to the internal design hydrocarbons, since this could result in the formation
pressure, whichever is lower, and a visual examination for of an explosive mixture. When necessary, the design
evidence of leaks at locations such as flanges, weld joints, service fluid can be used for pneumatic pressure
threaded connections, and any repaired locations should be testing.
conducted. (c) The fabrication and in-service inspection
(9) Test liquid should be drained immediately after
records, along with any necessary operational records,
completion of the hydrostatic test Care should be exercised should be reviewed prior to testing to determine if the
to provide proper venting to prevent the creation of internal pressure component/system has experienced a
negative pressure (vacuum) during draining. credible deterioration mechanism. Consideration
(-a) Pressure vessels and/or piping systems that should be given to how each mechanism could
will hold the test water for more than 10 days, whether or manifest itself.
not the test liquid is pressurized, should be treated with a (1) The inspection records should be reviewed
corrosion inhibitor and biocide. A corrosion engineer should for thinning beyond the specified limit. If thinning has
be consulted. occurred beyond the specified corrosion allowance, an
engineering evaluation shall be performed.

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(2) The component/system may have been damaged unacceptable, a limited access area and pressure control
by mechanical means such as high vibration. Consideration point should be established. The minimum distance from the
should be given to inspecting the entire system prior to boundary of this area to the pressurized component should
testing to look for evidence of damage. be calculated according to the procedure of Mandatory
(d) Components fabricated from brittle materials such as Appendix 501-111.
cast iron and ductile iron shall not be pneumatically When the spacing requirements described in Mandatory
pressure tested unless the following requirements are Appendix 501-III are not achievable, consideration should
adhered to: be given to the design, fabrication, and installation of an
(1) the pressure test does not exceed MAWP alternative barricade capable of withstanding the blast of
(2) additional NDE, such as Acoustic Emission (AE) stored energy within the system. See also para. (e).
testing, is performed along with the pressure test (i) Overpressure relief protection shall be provided. The
(3) the procedures from para. 501-6.2.1 are followed set pressure of a pressure relief device should be not more
(e) The maximum calculated stored energy of any vessel than the greater of
or piping system being pneumatically pressure tested (1) the test pressure plus 70 kPa (10 psi), or
should not be greater than 271 000 000 J (200,000,000 ft- (2) 110% of the test pressure
lb). When calculating the stored energy for a vessel, the total (j) The test pressure for a pneumatic pressure test for
volume shall be considered. When calculating the stored equipment should be according to the original construction
energy of a piping system, a maximum volume based on a code, considering also any subsequent engineering analysis
length of 8 pipe diameters may be considered for any single as deemed necessary.
failure analyzed. (k) If the requirements of the original construction code
(f) If the calculated stored energy is greater than 271 are not available, the test pressure for a pneumatic pressure
000 000 J (200,000,000 ft-lb), then one of the following shall test for pressure vessels shall be
occur:
(1) The system shall be divided into smaller volumes
such that each subsystem has a stored energy not greater
than 271 000 000 J (200,000,000 ft-lb). where
(2) A minimum distance shall be calculated per 1.1 = test factor
Mandatory Appendix 501-III, eq. (III-1), and this distance P= maximum allowable working pressure from the
shall be adhered to. Manufacturer’s Data Report If unknown, use the
(3) A barricade per (h) shall be installed. vessel's design or rated pressure.
(g) A detailed hazard analysis should also be performed Pt = test pressure to be used
to evaluate the risk associated with the release of stored Sat = allowable stress attest temperature from the
energy. See Mandatory Appendix 501-IV for considerations applicable construction code for the material of
relative to risk evaluation. Factors to consider in this which the component under consideration is
analysis should include: constructed
(1) any damage mechanisms identified by review of S dt = allowable stress at design temperature from
fabrication or in-service inspection records along with the applicable construction code for the
operational records material of which the component under
(2) the MDMT of the components being pressure consideration is constructed
tested, and its relative comparison to the test temperature to Sat/Sdt = ratio of allowable stresses; the lowest value
address the risk of brittle fracture shall be used in eq. (3) for all materials
(3) the stress level of the system while undergoing a considered
test (1) If the requirements of the original construction code
(4J the amount of nondestructive examination are not available, the test pressure for a pneumatic pressure
performed on welds that have not previously been subjected test for piping systems shall be
to a hydrostatic or pneumatic pressure test
(5) other simultaneous inspection methods being P t =1.1 x P (4)
performed during the pressure test such as acoustic where
emission (AE) testing 1.1 = test factor
(6) pressure wave from potential blast P = internal design pressure of the piping system
(7) size of potential fragments resulting from failure of P t = test pressure to be used
system, distance of travel, and existence of barriers sufficient
to stop fragment projectiles
(h) For pressure tests where the risk of injury from
potential fragments, shock waves, or other consequences of
any pressurized system failure is determined to be

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The stored energy of the equipment or piping (1) the test pressure divided by the test factor for
system under pneumatic pressure should be calculated vessels [see para. 501-6.2(j), eq. (3)]. If there is no test factor
and converted to equivalent pounds of TNT available, use 4/5 test pressure.
(Trinitrotoluene) using the equations shown in (2) design pressure for piping.
Mandatory Appendix 501-II. The value calculated may
be used for alternative safe distance calculations as per Step 4. See (a) through (c) of this Step.
Mandatory Appendix 501-III. The minimum safe (a) Conduct a complete inspection for leakage of the
distance shall be the greater of the distance required vessel or piping system, or both, at locations such as flanges,
by para. 501- III-1(a) or as calculated by Mandatory weld joints, and threaded connections.
Appendix 501-III, eq. (III-1). See also Mandatory NOTE: It is assumed that the integrity of the pressurized
Appendix 501-III, Table 501-III-2-1 when fragments system has been proven by Step 3(b) and the barricades
are to be considered. required by para. 501-6.2(e) can be safely passed.
NOTE: The stored energy value of 271 000 000 J (b) If no leakage is discovered, release system
(200,000,000 ft- lb) is equivalent to an explosive pressure.
energy of 127 lb of TNT. Risk evaluation may also be (c) If leakage that is not acceptable is discovered,
required; see (d) and Mandatory Appendix 501-IV. relieve all system pressure and repair. Repeat Steps 2 and 3.
(18) 501-6.2.1 Pneumatic Test Procedures. Step 5. After completion of the test, the vessel or piping
system, or both, should be restored to its design condition.
The items specified in Steps 1 through 5 should be This includes, but is not limited to, the following:
considered when developing pneumatic pressure test (a) All flanged joints blinded for pressure testing
procedures for vessels or piping systems. should be reassembled with new gaskets and tightened in
accordance with applicable specifications. Consideration
Step 1. See (a) through (e) of this Step- should be give to ASME PCC-1 guidelines.
(a) Raise pressure to the lesser of 170 kPa (25 (b) Vent and bleed connections that were installed
psi) or 25% of test pressure. solely for testing purposes should be plugged using
(b) Block in supply and hold for 10 min. materials and methods per the applicable specification.
(c) Visually inspect system for leaks. Consideration should be given to seal welding when
(d) If leaks are discovered, release pressure, necessary.
repair, and return to Step 1. 501-6.3 Tightness Test
(e) If no leaks are discovered, proceed to Step 2.
(a) A tightness test may be performed to detect leaks at
various locations within a pressure system. It may be
Step 2. Gradually increase system pressure to 50% performed on systems that have previously been pressure
of the test pressure as follows: tested, for closure welds of piping systems, on tube-to-
(a) Increase pressure in Step 1 by 350 kPa (50
tubesheet joints, and on systems exempted from hydrostatic
psi) or to 35% test pressure, whichever is greater. Hold or pneumatic testing. ASME BPVC, Section V, Article 10
for a minimum of 3 min to allow strains to equalize. provides information on a variety of leak testing methods.
Continue to increase by 350 kPa (50 psi) increments (b) A sensitive leak test per ASME B31.3 is the preferred
until the system pressure is at 50% test pressure. method for conducting a tightness test.
(b) Hold at 50% test pressure for a minimum of
(c) The applied test pressure for vessels and piping
10 min. Observe pressure gauge for loss of system should not exceed 35% of the design pressure. However,
pressure. If pressure loss exceeds 10% of test pressure, leakage at flanged joints may be evident at much lower
the system pressure should be reduced to 25% test pressures when using sensitive leak detection methods;
pressure and the system checked for leaks. therefore, the minimum test pressure should be specified
(c) If no loss of pressure is detected, subject to
which enables the test sensitivity requirements to be met.
approval of the inspector, proceed to Step 3. (d) Where the consequences of leakage of the process
medium are acceptable, an in-service leak test may be
Step 3. See (a) through (c) of this Step. performed as a tightness test using the process medium
(a) Gradually increase system pressure in
during the start-up of the system.
increments of 10% of test pressure. At each increment,
block supply and observe pressure gauge for 5 min.
If pressure loss is observed, reduce pressure to 501-6.3.1 Pneumatic Tightness Test
25% test pressure and check for leaks. If necessary, Procedures. The
release pressure and perform necessary repairs. items specified in (a) through (f) should be considered when
Return to Step 1. developing pneumatic tightness test procedures for vessels
(b) Once full test pressure is reached, block or piping systems.
supply and observe pressure gauge for a minimum of
10 min.
(c) Reduce system pressure to the following
applicable pressure:

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(a) Clean, dry, oil-free air should be used as the test ASME PTC 19.2, Pressure Measurement, Instruments and
medium, except in systems which cannot be verified as Apparatus
free from hydrocarbons. For this situation, nitrogen Geng, Jihui and Thomas, Kelly. "Evaluations of Pipe Loads
should be used as the test medium [see para. 501- from Blast Ruptures." Paper presented at the 51st ASME
6.2(b)]. Pressure Vessel and Piping Conference, Honolulu, HI, USA,
(b) To minimize the stored energy of a system, the July 2017. doi 10.1115/PVP2017-65186.
maximum test pressure should be not more than 35% of
the design pressure of the vessel or piping system. The (http://proceedings.asmedigitalcollection.asme.org/proc
test pressure should be no less than the lesser of 105 eeding.aspx?articleid=2660516&resultClick=3)
kPa (15 psi) or 25% of the system design pressure. Publisher: The American Society of Mechanical Engineers
(c) The system pressure should be gradually (ASME), Two Park Avenue, New York, NY 10016-5990
increased until the system pressure is the lesser of 170 (www.asme.org)
kPa (25 psi) or 25% of the test pressure. Hold at this
ISO 8573-1, Compressed Air— Part 1: Contaminants and
pressure long enough to conduct a preliminary
purity classes
inspection for leaks.
Publisher: International Organization for Standardization
(d) System pressure should be gradually increased
(ISO], Central Secretariat, Chemin de Blandonnet 8, Case
in increments of 10% of test pressure, holding for 30 s
postale 401, 1214 Vernier, Geneva, Switzerland
to 1 min at each increment Hold at final test pressure
(www.iso.org)
and complete a thorough inspection for leakage using
the Gas and Bubble test method specified in ASME BPVC, Recommended Practice No. No. SNT-TC-1A, Personnel
Section V, Article 10, or other method of equal or better Qualification and Certification in Nondestructive Tes
sensitivity. ANSI/ASNT CP-189-2006, ASNT Standard for Qualification
(e) If leakage is discovered and a joint needs to be and Certification of Nondestructive Testing Personnel
tightened, reduce system pressure to the lesser of 50% Batey, Jon E. "NDT Solution: Worried About Leaks? Don't
of test pressure or 170 kPa (25 psi) and tighten. Paint Before Hydrotesting." Materials Evaluation 51, no. 9
(f) After completion of the test, the vessel and/or (September 1993): 980-982.
piping system should be restored to its operating Publisher: American Society for Nondestructive Testing
condition. (ASNT), P. 0. Box 28518, 1711 Arlingate Lane, Columbus,
OH 43228-0518 (www.asntorg)
(18) 501-7 REFERENCES
The following is a list of publications referenced in Dobis, J. D., D. C. Bennett "Damage Mechanisms Affecting
this Article. Unless otherwise specified, the latest Fixed Equipment in the Pulp and Paper Industry."
edition shall apply. Welding Research Council Bulletin 488 (2004).
(https://www.forengineers.org/wrc-488.html)
API RP 571-1, Damage Mechanisms Affecting Fixed Dobis, J. D., J. E. Cantwell, M. Prager. "Damage Mechanisms
Equipment in the Refining Industry API 579-1/ASME Affecting Fixed Equipment in the Refining Industry."
FFS-1, Fitness-for-Service API RP 580, Risk-Based Welding Research Council Bulletin 489 (2004),
Inspection Publisher: American Petroleum Institute (https://www.forengineers.org/wrc-489.htmI)
(API], 1220 L Street, NW, Washington, DC 20005-4070 Dobis, J. D., D. N. French. "Damage Mechanisms Affecting Fixed
(www.api.org] Equipment in the Fossil Electric Power Industry." Welding
ASME Boiler and Pressure Vessel Code, Section II, Part Research Council Bulletin 490 (2004).
D —Properties (https://www.forengineers.org/wrc-490.html)
ASME Boiler and Pressure Vessel Code, Section V — Publisher: Welding Research Council (WRC), P.0. Box 20 1
Nondestructive Examination ASME Boiler and Pressure 547, Shaker Heights, OH 44120
Vessel Code, Section VIII, Division 1 — Rules for (www.forengineers.org)
Construction of Pressure Vessels ASME B16.5, Pipe IME SLP-2-2011 (2017), The American Table of Distances
Flanges and Flanged Fittings NPS 1/2Through NPS 24 Publisher: Institute of Makers of Explosives (IME), 1212 New
Metric/Inch Standard ASME B31.3, Process Piping (See York Avenue NW, Suite 650, Washington D.C. 20005-6155
Appendix F for considerations of damage mechanisms.) (www.ime.org)
ASME PCC-1, Guidelines for Pressure Boundary Bolted
Flange Joint Assembly

250
 ASME PCC-2-2018

Mandatory Appendix 501-I

(18) Pressure/Leak Testing

This Appendix provides an example of a design data

sheet as referenced in para. 501-3.5.

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Mandatory Appendix 501-II

(18) Stored Energy Calculations for Pneumatic Pressure Test

501-II-1 GENERAL
The stored energy of the equipment or piping system
should be calculated and converted to equivalent kilograms
(pounds) of TNT [Trinitrotoluene) using the following
equations:

where
E = stored energy, J (ft-lb)
k = ratio of specific heat for the test fluid
P a = absolute atmospheric pressure, 101 kPa (14.7
psia)
P at = absolute test pressure, Pa (psia)
V = total volume under test pressure, m3 (ft3)

When calculating the stored energy for a vessel, the

total volume shall be considered. When calculating the
stored energy of a piping system, a maximum volume
based on a length of of 8 pipe diameters may be
considered for any single failure analyzed.
See also paras. 501-6.2(e) and 501-6.2(f).

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Mandatory Appendix 501-III

Safe Distance Calculations for Pneumatic Pressure Test
501- III-1 BLAST WAVE DISTANCE For example, to prevent lung damage, the distance a
The minimum distance between all personnel and the person is from the equipment should result in an Rscaled
equipment being tested shall be the greater of value of more than 6 m/kg1/3 (15 ft/lb1/3). Note the
(a) the following: structural damage that can occur, which shall be
(1) R = 30 m for E  135 500 000 J considered.
(2) R = 60 m for 135 500 000 J < E  271 000 000 J
(3) R = 100 ft for E < 100,000,000 ft-lb 501- III-2 FRAGMENT THROW DISTANCE
(4) R = 200 ft for 100,000,000 < E  200,000,000 ft-lb (a) When fragments of vessel or piping are at risk of
(b) the following equation: being created and impacting personnel, the minimum
distance between all persons and the equipment being
tested shall be as shown in Table 501-III-2-1.
(b) If the distances in Table 501-III-2-1 are not
where achievable, the distance may be evaluated using methods
E = stored energy as calculated by Mandatory avail- able in the public domain.
Appendix 501-II, eq. (II-1) or eq. (II-2)
R = actual distance from equipment
Rscaled = scaled consequence factor; value for eq. (III- 1)
shall be 20 m/kg1/3 (50 ft/lb1/3) or greater
TNT = energy measured in TNT, kg (lb), determined from
Mandatory Appendix 501-II, eq. (II-3) or eq. (II-53)
For systems where E > 271 000 000 J (200,000,000 ft-
lb), the required distance shall be calculated by eq. (III-1).
If the minimum calculated distance cannot be obtained,
an alternative value for Rscaled may be chosen based on
Table 501-III-1-1 for use in eq. (III-1). See also para. 501-
6.2(g).

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Mandatory Appendix 501-IV

(18) Risk Evaluation Considerations for Pneumatic Pressure Test

501-IV-1 INTRODUCTION (b) an existing carbon steel vessel with an MDMT rating
of -45°C (-50°F) into which a new nozzle had been installed
When considering the risk analysis factors listed in para.
following all requirements of the original construction code.
501-6.2(f), it should be remembered that risk is a two-
The vessel has a total volume that results in an energy level
dimensional combination of probability (or likelihood) and
greater than 271 000 000 J (200,000,000 ft-lb); however, it
consequence. Risk is the measure of the potential for harm
is still desirable to perform a pressure test to check the
or loss (i.e., hazard] that reflects the likelihood (or
integrity of the weld and obtain the other benefits of
frequency) and severity of an adverse effect to health,
pressure testing. It is not feasible to install blast barriers. By
property, or the environment If probability and consequence
performing volumetric examination such as UT on the nozzle
are defined quantitatively (i.e., numerical values are
attachment weld and determining the weld is free of
assigned], risk is the product
rejectable indications, along with verification by inspection
risk = probability X consequence (IV-1) that the vessel is in a like-new condition, the risk associated
with a full pneumatic pressure test of this vessel may be
In a qualitative assessment, a matrix is typically used to
deemed acceptable.
combine probability and consequence. Consideration should
(c) When considering the volume of piping to complete
be given to the level of risk that is acceptable when
stored energy calculations, the use of 8 pipe diameters may
performing pneumatic tests. Reference API RP 580 for use of
not be sufficient
risk assessment in determining the acceptable levels of risk (1) brittle failure or failure along the length of a poor
associated with pneumatic testing. longitudinal weld seam, where the actual opening may
In reviewing eq. (IV-1), it is clear that even though the be instantaneous and the release of energy larger than
consequence may be significant, if the probability is very low that as calculated by 8 pipe diameters
the risk may become acceptable. For example, the (2) installations where the pipe or pipeline is not
consequence of an airliner crashing is significant in that it restrained and can become a projectile; see Table 501-
will most likely result in serious injury or death to the III-2-1
passengers along with major damage to or total loss of the
aircraft However, the probability of an airliner crashing is 501-IV-3 PIPING SYSTEM VOLUME CONSIDERATIONS
very low; thus, the public accepts the risk associated with A schematic illustration of the pipeline rupture leading
airline travel. to burst explosion is shown in Figure 501-IV-3-1. The
volume of gas that should be included within the stored
501-IV-2 PNEUMATIC TEST RISK CONSIDERATIONS energy calculation is not just the volume contained within
Risk considerations can be applied to pneumatic testing the pipe length that has ruptured, but should include a
also. Examples may include section of each end of pipe that is starting to depressurize,
(a) a new austenitic stainless steel piping system that has given as d in Figure 501-IV-3-1. The distance d can be
been hydrostatically tested during shop fabrication, with the calculated by considering the speed that information about
exception of four final field assembly circumferential butt the loss of containment can travel down the pipe. When the
welds. The piping system has a total volume that results in rupture occurs, the shock wave of the rupture travels down
an energy level greater than 271 000 000 ) (200,000,000 ft- the pipe at the speed of sound of the compressed gas. The
lb); however, it is not feasible to separate the piping system shock wave for this type of explosion has a typical signature
into smaller sections for testing, nor is it feasible to install shape with a steep rise time. The exact rise time would vary
blast barriers. By performing volumetric examination such for each incident, but will be less than the measured rise time
as UT or RT and determining the field welds are free of within a deflagration explosion (which has a shallower
rejectable indications, the risk associated with a full profile initially] and is consequently less than 10 ms.
pneumatic pressure test of this system may be deemed
acceptable.

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1Gengand Kelly. "Evaluation of Blast Loads from Pipe Ruptures."

Paper presented at the 51st ASME PVP Conference, Honolulu, HI,
July 2017.

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Article 502
Nondestructive Examination in Lieu of Pressure Testing for
Repairs and Alterations

(b) Pneumatic Test This is performed in

502-1DESCRIPTION some situations where the presence of any water
or weight of the water in the system is an issue. The
502-1.1 Background pneumatic test is potentially hazardous due from
This Article provides alternatives to pressure testing after the stored energy of the compressed gas.
repairs or alterations. A pressure test in itself is a useful tool (c) Hydro-Pneumatic Test This is a
with respect to newly constructed equipment Application of combination of the two other test methods. Article
a pressure test, to equipment that has been in service for 501 should be referred for pressure testing issues
some time, is a matter that requires careful consideration of and precautions.
a variety of factors involved. There are instances where the
application of a pressure test is not desirable, such as, the 502-1.4 Nondestructive Examination (NDE)
application of a pressure test may create damage. NDE has been defined as comprising those
examination methods (see Mandatory Appendix 502-1)
502-1.2 Application used to examine an object, material, or system without
This Article applies to equipment for which j impairing future usefulness. It is used to investigate the
(a) NDE provides better assurance of integrity in future material and component integrity.
operation for elevated temperature or cyclic operation Determining the structural integrity of a
where crack initiation and propagation is a concern. Large pressure- retaining device or component can be
flaws may not result in failure during a pressure test but may accomplished by a process involving a quantitative
propagate in cyclic or creep service. engineering evaluation coupled with NDE to obtain
(b) a pressure test is not practical and NDE can be shown current wall thicknesses and provide detection and
to provide appropriate integrity assurance. A pressure test sizing of any in-service flaws or cracks (National
of equipment that has been repaired is primarily a leak test, Board Bulletin, Volume 61).
or, in some cases, a test for gross fabrication flaws that could
compromise structural integrity. Structural integrity of the 502-1.5 Pressure Test
design is usually not an issue for repairs. Even for most 502-1.5.1 Reasons for Pressure Testing in New
alterations, the integrity of the design can be verified by (18) Construction
engineering analysis.
(a) Checks for leakage of mechanical and welded joints
(c) a pressure test is practical, but NDE can be shown to
(b) May avoid an in-service failure and associated
provide equivalent integrity assurance. In this case, overall
safety issues
cost may be a major consideration. It is essential that the
(c) Screens out gross design, material, fabrication
appropriate NDE be performed based on the damage
deficiencies
mechanisms anticipated during repairs or alterations.
(d) Reduces the stress-multiplying capability of
502-1.3 Pressure Testing sharp notches, metallurgical defects,
Pressure testing consists of three primary methods. discontinuities (flaw tip blunting)
(a) Hydrostatic Test The fluid used is typically water; (e) Provides mechanical stress relief Also refer to 501-
however, another suitable liquid can be substituted if there 3.2.
is a risk of damage due from any adverse effects of having 502-1.6 NDE Methods (18)
water in the system. The following is a limited list of the more
common alternative NDE methods. Mandatory
Appendix 502-1, Table 502-I-1 compares NDE
methods, properties sensed or measured, typical
discontinuities detected, representative
applications, advantages, and limitations. Refer to
section 502-5 for examination requirements.

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502-2.3.2 Undesirable Reactions or Consequences.

502-1.6.1 Alternative NDE Methods: Volumetric A safety concern where the application of test fluids could
lead to an undesirable reaction with the residue of fluids
(a) Radiography
contained in the pressure equipment
(b) Ultrasonic shear wave
502-2.3.3 Design Reasons
(c) Automated ultrasonics, such as time-of-flight-
diffraction (TOFD) and phased array ultrasonics (a) Where the design of the pressure equipment is based
on other factors, such as bending, where stresses due to
502-1.6.2 Alternative NDE Methods: Surface pressure may not be governing
(b) Where a vessel for which the thickness of the
(a) Magnetic particle pressure boundary components is governed by external
(b) Liquid penetrant pressure (buckling) considerations
(c) Eddy current
(d) Magnetic flux leakage 502-2.3.4 Painting/Coating/Lining Issues.
Where painting/coating/lining could mask leaks that would
(18) 502-1.7 Brittle Fracture Risk otherwise have been detected during a pressure test This
includes damage to refractory or other insulating internal
Performing pressure tests of an in-service device or
materials as well as damage to internal linings.
component with inadequate fracture toughness could
result in brittle fracture. Once a device or component 502-2.4 Repairs and Alterations for Which
has been subjected to a one-time (at new construction) Pressure Testing Is Not Normally Required
hydrostatic test, any additional hydrostatic tests over (ANSI/NB-23)
the life of the component will serve minimal useful
purpose regarding structural integrity or benefits of The following types of repairs and/or alterations may be
redistribution of stresses. exempt from pressure testing or where pressure tests may
In addition, performing a hydrostatic test above the be optional depending upon the needs of the owner- user:
normal working pressure of an in-service component (a) welding or brazing that does not penetrate the
can result in significant exposure to brittle fracture — pressure boundary at any point
especially if the material of construction: (b) seal welds
(a) has been subjected to some degree of (c) cladding application/repairs
embrittlement under normal service conditions (d) hard surfacing
(b) possesses poor fracture toughness as a result of (e) welding to flange seating surfaces, when less than
steel melting practices 50% of the axial thickness is replaced by welding
(c) contains an undetected critical flaw from in- (J) tube-to-tube sheet welds, provided less than 10% of
service exposure, or the total number of tubes are replaced at any time after a full
(d) will be pressure tested below the DTB operational cycle
transition temperature of any component (g) tube plugging or sleeving of heat exchangers, steam
generators, or boiler tubes
502-2 LIMITATIONS (h) hot tap fittings
502-2.1 Alternative Requirements: Part 1 of
ASME PCC-2 502-3 DESIGN
Part 1 of this Standard contains additional See para. 502-2.3.3.
requirements and limitations. This Article shall be used
502-4 FABRICATION (REPAIR OR ALTERATION)
in conjunction with Part 1.
In the context of this Article, this is not applicable.
502-2.2 Repaired or Altered Pressure Equipment
502-5 EXAMINATION — NONDESTRUCTIVE
The terms repaired and altered are as defined in EXAMINATION (NDE)
the National Board Inspection Code (NBIC), ANSI/NB-
23 Appendix 4, or API 510 and API 570 for pressure The specific type and amount of surface and/or
vessels and piping. volumetric NDE that should be specified in lieu of pressure
testing is at the owner-user’s discretion, the extent of which
502-2.3 Examples Where Pressure Test May Be should be based on the risk of leak or failure of the
Inadvisable equipment. The NDE specified needs to match the
502-2.3.1 Foundation or Support Structure.
Where the foundation or supporting structure has not been
designed to carry the weight of liquid-filled pressure
equipment

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likelihood of the type of defects that could occur with ASME Boiler and Pressure Vessel Code, 2007 Edition, Section
the particular materials and welding methods in use. V, Nondestructive Examination
See para. 502-1.6 for the more common NDE methods ASME Boiler and Pressure Vessel Code, 2007 Edition, Section
generally employed in lieu of pressure testing. VIII, Division 1 — Rules for Construction of Pressure
Vessels
502-6 TESTING ASME Boiler and Pressure Vessel Code, 2007 Edition, Section
IX, Qualification Standard for Welding and Brazing
In the context of this Article, this is not applicable.
Procedures, Welders, Brazers, and Welding and Brazing
(18) 502-7 REFERENCES Operators
ASME Boiler and Pressure Vessel Code, 2007 Edition, Code
The following is a list of publications referenced in
Case 2235
this Article. Unless otherwise specified, the latest
Publisher: The American Society of Mechanical Engineers
edition shall apply.
(ASME), Two Park Avenue, New York, NY 10016-5990
ANSI/NB-23-2007, National Board Inspection Code (www.asme.org)
Publisher: National Board of Boiler and Pressure
ASNT Recommended Practice No. SNT-TC-1A, Personnel
Vessel Inspectors (NBBI), 1055 Crupper Avenue,
Qualification and Certification in Nondestructive Testing
Columbus, OH 43229-1183 (www.nationalboard.org)
Publisher: American Society for Nondestructive Testing
API 510-2006, Pressure Vessel Inspection Code: (ASNT), P. 0. Box 28518, 1711 Arlingate Lane, Columbus,
Maintenance Inspection, Rating, Repair, and OH 43228-0518 (www.asntorg)
Alteration API 570, In-Service Inspection Code for Galanes, George. "Pressure Testing: Fact and Fiction,"
Process Piping Publisher: American Petroleum National Board Bulletin 61, no. 3 (Fall 2006):28
Institute (API), 1220 L Street, NW, Washington, DC (https://www.nationalboard.org/SiteDocuments/
20005 (www.api.org) Bulletins/FA06.pdf).
ASME Boiler and Pressure Vessel Code, 2007 Edition,
Section IV, Heating Boilers

260
 ASME PCC-2-2018

Mandatory Appendix 502-I

Comparison of Selected NDE Methods
See Table 502-I-1.

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ASME PCC-2-2018

262
ASME PCC-2-2018

263