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ASME PCC-2 Repair of Pressure Equipment and Piping, 2015
- CONTENTS
- FOREWORD
- PREPARATION OF TECHNICAL INQUIRIES
- COMMITTEE ROSTER
- CORRESPONDENCE WITH THE PCC COMMITTEE
- SUMMARY OF CHANGES
- PART 1 SCOPE, ORGANIZATION, AND INTENT [Go to Page]
- 1 SCOPE
- 2 ORGANIZATION
- 3 INTENT
- Table 1 Guide for the Selection of Repair Technique
- PART 2 WELDED REPAIRS [Go to Page]
- Article 2.1 Butt-Welded Insert Plates in Pressure Components [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION OF WELDS
- 6 PRESSURE TESTING
- Fig. 1 Flush Insert in Pipe or Tube
- Fig. 2 Flush Insert Plate (With or Without Nozzle/Manway) With Its Butt Weld Intersecting Existing Butt Weld in Shells or Heads
- Fig. 3 Intersecting “Doghouse” Type Insert Plate Butt Weld (With or Without Nozzle/Manway) With Shell Butt Weld in Vessel Shells and Heads
- Article 2.2 External Weld Buildup to Repair Internal Thinning [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Fig. 1 Weld Buildup Profile
- Article 2.3 Seal- Welded Threaded Connections and Seal Weld Repairs [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 2.4 Welded Leak Box Repair [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- Fig. 1 Example of a Welded Leak Box Repair of a Tee
- Article 2.5 Welded Lip Seals
- Article 2.6 Full Encirclement Steel Reinforcing Sleeves for Piping [Go to Page]
- 1 DESCRIPTION
- 2 CAUTIONS AND LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 6 TESTING
- 7 REFERENCES
- Fig. 1 Type A Sleeve
- Fig. 2 Type B Sleeve
- Fig. 3 Welded Split Sleeve for Use Over a Girth Weld
- Fig. 4 Type B Sleeve Fillet Weld Size for Sleeve Thickness Less Than or Equal to 1.4 Times the Carrier Pipe Thickness
- Fig. 5 Type B Sleeve Fillet Weld Size for Sleeve Thickness Greater Than 1.4 Times the Carrier Pipe Thickness
- Article 2.7 Fillet Welded Patches With Reinforcing Plug Welds [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Fig. 1 Typical Shell Repair Near Discontinuity
- Article 2.8 Alternatives to Traditional Welding Preheat [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- Fig. 1 Typical Residual Stresses in a Weld
- Fig. 2 Effect of Weld Area on Transverse Shrinkage
- Table 1 Comparison of Specification and Actual Weld Metal Properties
- Fig. 3 Typical Back Stepping Weld Sequence
- Fig. 4 Difference Between Oscillated Stringer Beads (Left) and Wide Weave Beads (Right)
- Fig. 5 Effect of Weld Bead Cross Section on Cracking
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 2.9 Alternatives to Postweld Heat Treatment [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- Table 1 Summary of Postweld Heat Treatment Requirements and Potential Alternatives
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 2.10 In- Service Welding Onto Carbon Steel Pressure Components or Pipelines [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- Table 1 Type and Number of Test Specimens Required for an In- Service Welding Procedure Qualification
- Fig. 1 Heat-Affected Zone Hardness Indent Locations
- Fig. 2 Mandrel Location Relative to the Weld Toe When Doing Face Bend Test for a Typical In-Service Fillet Weld
- Fig. 3 Examples of In-Service Welding Procedure Qualification Face Bend Test Samples
- Fig. 4 Test Sample Locations for In-Service Fillet Welding Procedure Qualification Assuming Equal Spacing Around the Circumference to Obtain All the Required Test Specimens
- Fig. 5 Test Sample Locations for In-Service Attachment Welding Procedure Qualification Assuming Equal Spacing Around the Circumference to Obtain All the Required Test Specimens
- Fig. 6 Test Sample Locations for In-Service Weld Metal Buildup Welding Procedure Qualification
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 2.10, Mandatory Appendix I In- Service Welding Procedure/ Welder Performance Qualification Setup
- Article 2.11 Weld Buildup, Weld Overlay, and Clad Restoration [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 2.12 Fillet Welded Patches [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 2.13 Threaded or Welded Plug Repairs [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 2.14 Field Heat Treating of Vessels [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 2.14, Mandatory Appendix I Developing a Heat Treatment Procedure
- Article 2.14, Mandatory Appendix II Typical Hot Box Design
- PART 3 MECHANICAL REPAIRS [Go to Page]
- Article 3.1 Replacement of Pressure Components [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 3.2 Freeze Plugs [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- Fig. 1 Nitrogen Freeze Plug Assembly
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- Article 3.3 Damaged Threads in Tapped Holes [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- Fig. 1 Example of Tapered Stud
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 3.3, Mandatory Appendix I Recommended Detail for Stud Threads Modification to Prevent Damage to Threads in Tapped Holes
- Article 3.3, Mandatory Appendix II An Illustrative Example Showing an Engineering Analysis Associated With Enlarging a Tapped Hole [Go to Page]
- II- 1 EXAMPLE 1
- II- 2 EXAMPLE 2
- Article 3.4 Flaw Excavation and Weld Repair [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- Fig. 1 Excavation and Weld Repair of Surface Flaw
- Fig. 2 Excavation and Weld Repair of Embedded Flaw
- 3 DESIGN
- Fig. 3 Grinding of Weld Flaw
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 3.4, Mandatory Appendix I Metal Removal Process [Go to Page]
- I- 1 FLAPPING
- I- 2 GRINDING
- I- 3 HONING
- I- 4 LAPPING
- I- 5 MACHINING
- I- 6 THERMAL GOUGING
- I- 7 BOAT SAMPLE CUTTING
- Article 3.5 Flange Repair and Conversion [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Fig. 1 Flange Dimensions
- Article 3.6 Mechanical Clamp Repair [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- Fig. 1 Example of a Mechanical Clamp
- Fig. 2 Square Mechanical Clamp Over Drain Branch, With Sealant Injection Nozzle
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 3.7 Pipe Straightening or Alignment Bending [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCE
- Article 3.8 Damaged Anchors in Concrete ( Postinstalled Mechanical Anchors) [Go to Page]
- 1 DESCRIPTION
- Fig. 1 Anchors
- 2 LIMITATIONS
- Fig. 2 Anchor and Concrete Failure
- 3 DESIGN
- Fig. 3 Column Base Anchors in Concrete
- Fig. 4 Weld Repair of Existing Rod
- 4 FABRICATION
- Fig. 5 Wedge Anchor
- Fig. 7 Relocation of One or Two Anchors Within an Arc (r = 1⁄2d)
- Fig. 8 Relocation of One or Two Anchors Within an Arc (r = d)
- Fig. 9 Relocation of One or Two Anchors Within a Design Plate Assembly
- Fig. 10 Relocation of More Than Two Anchors Within a Design Plate Assembly
- Fig. 11 Using an Enlarged Plate
- Table 1 Minimum Edge Distance for Punched, Reamed, or Drilled Holes
- Table 2 Expansion Anchor — Illustrative Example of Typical Minimum Limits for Reference
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 3.8, Mandatory Appendix I Anchors Installation Using Chemical Means ( Adhesive) [Go to Page]
- I- 1 Adhesive Anchors
- Article 3.9 Valves With Pressure Seal- Type Bonnets
- Article 3.10 Hot Bolting
- Article 3.11 Hot and Half Bolting Removal Procedures [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 3.12 Inspection and Repair of Shell and Tube Heat Exchangers [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION
- Fig. 1 Typical Friction Fit Tapered Tube Plug
- Fig. 2 Typical Mechanical Fit Tube Plugs
- Fig. 3 Typical Installation of Mechanical Fit Tube Plugs
- Fig. 4 Sample Chart: Number of Tube Failures by Month
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 3.12, Mandatory Appendix I Methods for Determining Minimum Number of Tubes to Inspect [Go to Page]
- I- 1 Introduction
- Table I- 1 Inspection Effectiveness Table
- Table I- 1 Inspection Effectiveness Table ( Cont'd)
- Article 3.12, Mandatory Appendix II Examination of Pressure Containment Components [Go to Page]
- II- 1 EXAMINATION
- II- 2 INSPECTION
- II- 3 SUITABILITY
- PART 4 NONMETALLIC AND BONDED REPAIRS [Go to Page]
- Article 4.1 Nonmetallic Composite Repair Systems: High-RiskApplications [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- Table 1 Repair System Required Material and Performance Properties
- Table 1 Repair System Required Material and Performance Properties ( Cont'd)
- Table 2 Service Temperature Limits for Repair Systems
- Table 3 Allowable ( Long Term) Strains for Repair Laminates ( No Allowance for Temperature Effects)
- Table 4 Service Factors for Repair Laminates
- 4 FABRICATION (INSTALLATION)
- Fig. 1 Schematic of a Repair System and Location of Defects
- Table 5 Hold Points During Installation
- 5 EXAMINATION
- Table 6 Defect Type and Allowable Limits for the Composite Wrap
- 6 SYSTEM PRESSURE TESTING
- 7 REFERENCES
- Article 4.1, Mandatory Appendix I Design Data Sheet
- Article 4.1, Mandatory Appendix II Qualification Data for the Repair System [Go to Page]
- II- 1 INTRODUCTION
- II- 2 DATA FOR REPAIR LAMINATE
- II- 3 DATA FOR REPAIR/ SUBSTRATE INTERFACE
- II- 4 ADDITIONAL REQUIREMENTS FOR STRUCTURAL REPAIRS TO NONLEAKING COMPONENTS ( TYPE A DESIGN CASE)
- II- 5 ADDITIONAL REQUIREMENTS FOR LEAKING COMPONENTS ( TYPE B DESIGN CASE)
- II- 6 PERFORMANCE TESTING ( OPTIONAL QUALIFICATION TESTS)
- Article 4.1, Mandatory Appendix III Short- Term Pipe Spool Survival Test [Go to Page]
- III- 1 INTRODUCTION
- III- 2 METHOD
- III- 3 REPORT
- Article 4.1, Mandatory Appendix IVMeasurement of y for Leaking Defect Calculation
- Article 4.1, Mandatory Appendix V Measurement of Performance Test Data [Go to Page]
- V- 1 INTRODUCTION
- V- 2 METHODS
- V- 3 REPORT
- Article 4.1, Mandatory Appendix VI Measurement of Impact Performance [Go to Page]
- VI- 1 INTRODUCTION
- VI- 2 METHODS
- VI- 3 REPORT
- Article 4.1, Mandatory Appendix VII Installer Qualification [Go to Page]
- VII- 1 INTRODUCTION
- VII- 2 TRAINING
- VII- 3 TRAINING RECORDS
- VII- 4 REQUALIFICATION
- Article 4.1, Mandatory Appendix VIII Installation [Go to Page]
- VIII- 1 INTRODUCTION
- VIII- 2 SURFACE PREPARATION
- VIII- 3 LAMINATE LAY- UP
- VIII- 4 CURE
- VIII- 5 DOCUMENTATION
- Article 4.1, Nonmandatory Appendix A Glossary of Terms and Acronyms [Go to Page]
- A- 1 GLOSSARY OF TERMS
- A- 2 GLOSSARY OF ACRONYMS
- Article 4.1, Nonmandatory Appendix B Recommended Retesting for a Modified Qualified Repair System [Go to Page]
- B- 1 GENERAL
- B- 2 MODIFIED REPAIR SYSTEM
- B- 3 ENGINEERING JUDGMENT
- Table B- 1 Recommended Testing for Requalification of a Modified Qualified Repair System
- Table B- 1 Recommended Testing for Requalification of a Modified Qualified Repair System ( Cont'd)
- Table B- 1 Recommended Testing for Requalification of a Modified Qualified Repair System ( Cont'd)
- Article 4.2 Nonmetallic Composite Repair Systems: Low- Risk Applications [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- Table 1 Repair System Required Material and Performance Properties
- 4 FABRICATION ( INSTALLATION)
- Table 2 Hold Points During Installation
- 5 EXAMINATION
- Table 3 Defect Type and Allowable Limits for the Composite Repair
- 6 SYSTEM PRESSURE TESTING
- 7 REFERENCES
- Article 4.2, Mandatory Appendix I Repair Data Sheet
- Article 4.2, Mandatory Appendix II Qualification Data for Repair System [Go to Page]
- II- 1 INTRODUCTION
- II- 2 DATA FOR REPAIR LAMINATE
- II- 3 DATA FOR COMPOSITE/ SUBSTRATE INTERFACE
- II- 4 ADDITIONAL REQUIREMENTS FOR LEAKING SUBSTRATES
- Article 4.2, Mandatory Appendix III Validation for Repair of Leaking Component [Go to Page]
- III- 1 INTRODUCTION
- III- 2 METHOD
- III- 3 REPORT
- Article 4.2, Mandatory Appendix IV Installer Qualification [Go to Page]
- IV- 1 INTRODUCTION
- IV- 2 TRAINING
- IV- 3 RECORD OF TRAINING
- IV- 4 QUALIFICATION PERIOD
- Article 4.2, Mandatory Appendix V Installation [Go to Page]
- V- 1 INTRODUCTION
- V- 2 SURFACE PREPARATION
- V- 3 LAMINATE LAY- UP
- V- 4 CURE
- V- 5 DOCUMENTATION
- Article 4.2, Nonmandatory Appendix A Glossary of Terms and Acronyms [Go to Page]
- A- 1 GLOSSARY OF TERMS
- A- 2 GLOSSARY OF ACRONYMS
- Article 4.3 Nonmetallic Internal Lining for Pipe: Sprayed Form for Buried Pipe [Go to Page]
- 1 DESCRIPTION
- 2 CAUTIONS AND LIMITATIONS
- 3 DESIGN
- 4 FABRICATION ( INSTALLATION)
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 4.3, Mandatory Appendix I Design Considerations for Buried Pipe [Go to Page]
- I- 1 WALL THICKNESS OF CIPP
- I- 2 DESIGN EQUATIONS
- I- 3 APPLIED LOADS DESIGN
- Article 4.3, Mandatory Appendix II Inspection/ Examination and Corrective Action Requirements for CIPP [Go to Page]
- II- 1 GENERAL
- II- 2 POLYMER MIXTURE
- II- 3 POLYMER THICKNESS SAMPLING
- II- 4 POLYMER HARDNESS
- II- 5 POLYMER COVERAGE
- II- 6 SURFACE DEFECT CORRECTIVE ACTIONS
- II- 7 CORRECTIVE ACTION FOR AREAS OF INSUFFICIENT CURING
- Article 4.3, Mandatory Appendix III Glossary of Terms and Acronyms [Go to Page]
- III- 1 GLOSSARY OF TERMS
- III- 2 GLOSSARY OF ACRONYMS
- PART 5 EXAMINATION AND TESTING [Go to Page]
- Article 5.1 Pressure and Tightness Testing of Piping and Equipment [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- Fig. 1 Test Type Selection
- 4 FABRICATION
- 5 EXAMINATION
- 6 TESTING
- 7 REFERENCES
- Article 5.1, Mandatory Appendix I Pressure/ Leak Testing
- Article 5.1, Mandatory Appendix II Stored Energy Calculations for Pneumatic Pressure Test
- Article 5.1, Mandatory Appendix III Safe Distance Calculations for Pneumatic Pressure Test [Go to Page]
- III- 1 BLAST WAVE DISTANCE
- Table III- 1 Alternative Values for
- III- 2 FRAGMENT THROW DISTANCE
- Table III- 2 Minimum Distances for Fragment Throw Considerations
- Article 5.1, Mandatory Appendix IV Risk Evaluation Considerations for Pneumatic Pressure Test
- Article 5.2 Nondestructive Examination in Lieu of Pressure Testing for Repairs and Alterations [Go to Page]
- 1 DESCRIPTION
- 2 LIMITATIONS
- 3 DESIGN
- 4 FABRICATION ( REPAIR OR ALTERATION)
- 5 EXAMINATION — NONDESTRUCTIVE EXAMINATION ( NDE)
- 6 TESTING
- 7 REFERENCES
- Article 5.2, Mandatory Appendix I Comparison of Selected NDE Methods [Go to Page]
- Table I- 1 Comparison of Selected NDE Methods
- Table I- 1 Comparison of Selected NDE Methods ( Cont'd) [Go to Page]