ASME PCC-2 Post Construction Specifications - Episode 2 (Part 2: Welding Repairs)

Introduction to Athabasca Engineering Solutions

Overview of AES Services

• Chris Kurzick introduces himself as the principal engineer at Athabasca Engineering Solutions (AES).

• AES provides various services including third-party value evaluations, training and certification, and equipment re-rating.

Continuing PCC2 Weld Repairs Presentation

Focus on Article Discussions

• The presentation continues with part two of the discussions on PCC2 weld repairs, covering 16 articles in total.

Article 209: Alternatives to Post Weld Heat Treating

Situations Requiring Alternative Methods

• Discusses scenarios where post-weld heat treating is not feasible, such as when dealing with live lines or chrome moly alloys.

Temper Bead Welding Technique

• Introduces temper bead welding, a method developed in the nuclear industry for managing heat input during welding processes.

Article 210: In-Service Welding Concerns

Key Considerations for Welding on Pressurized Components

• Highlights concerns about burning through pipe walls and hydrogen cracking due to local heating during welding.

Techniques for Control

• Emphasizes the importance of controlling cooling rates and using techniques like temper bead welding to mitigate risks.

Limitations of In-Service Welding Techniques

Applicability Restrictions

• Notes that these techniques are primarily applicable to carbon steel and may not be suitable for chrome moly or stainless steel.

Article 211: Weld Build-Up and Overlay Restoration

Types of Restoration Processes

• Describes three main sections: weld overlay for corrosion resistance, weld build-up for restoring worn surfaces, and clad restoration methods.

Application Context

• Indicates that while focused on refineries, these methods can also be adapted for mining applications.

Article 212: Using Weld Patches with Fillet Welds

Repair Methodology

• Explains the use of fillet weld patches along plate edges as a repair method similar to article 207 but focusing solely on fillet weld applications.

Challenges in Matching Contours

• Discusses the difficulty in accurately matching contours when repairing wall thinning across various shapes.

Threaded or Welded Plug Repairs

Flaw Removal Process

• Details procedures involving drilling out defects followed by inserting solid or threaded plugs sealed with welding.

Access Considerations

• Mentions this method's utility in gaining access for inspection purposes within components.

Field Heat Treating Hazards

Risks Associated with Heat Treatment

• Warn about hazards like structural instability during heat treatment processes which could lead to material degradation or collapse.

Recommendations for Safety Measures

• Suggest strategies to manage thermal expansion issues and ensure structural integrity during field operations.

Article 215: Welding Repair Considerations for Chrome Moly Vessels

Challenges in Chrome Moly Welding

Overview of Deterioration Mechanisms and Repair Methods

Common Issues in Turnarounds

• The speaker discusses common issues encountered during turnarounds, particularly focusing on skirt attachment welds. They mention the availability of extensive resources from API (American Petroleum Institute) for further information.

• Key problems highlighted include well seam failure, hydrogen-assisted cracking, and hydrogen cracking, which are significant concerns in the industry.

High-Level Overview of Deterioration Mechanisms

• A high-level overview is provided regarding deterioration mechanisms that should be considered when developing a detailed repair plan.

• The discussion includes examples of damage to guide professionals in identifying issues effectively.

Summary of Repair Methods

• The article summarizes various repair methods and offers a roadmap for next steps in addressing identified issues.

Welded Hot Taps in Pressure Equipment

• Article 216 focuses on welded hot taps used in pressure equipment or pipelines, explaining the process of welding a tee or fitting onto a pipeline before drilling into it with specialized equipment.

Considerations for Carbon Steel Lines

• PCC2 provides advice specifically for carbon steel lines, emphasizing factors like flow rates that can affect weld cooling during operations.

• It is important to maintain minimum tank levels as per API 653 guidelines to avoid overstressing the shell during hot tap operations.

Calculations Required During Welding Operations

• When welding onto pipes, calculations such as burn-through calculations are necessary to ensure sufficient material remains after welding to maintain structural integrity.

• External pressure calculations must also be performed prior to pressurizing connections post-welding to prevent local collapse of the pipe.

Detailed Codes and Further Information