PCC-2 Edtn 2008 PDF

Copyright 2009 by the American Society of Mechanical Engineers.
No reproduction may be made of this material without written consent of ASME.

uate cf lssuance: Aprll 7, 2009
Thls Standard wlll be revlsed when the Scclety apprcves the lssuance cf a new edltlcn. Thls Standard
wlll beccme effectlve 6 mcnths after the uate cf lssuance. There wlll be nc addenda lssued tc thls
edltlcn.
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http:]]cstccls.asme.crg as they are lssued.
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The Amerlcan Scclety cf Mechanlcal Fnglneers
Three Park Avenue, hew Ycrk, hY 10016-5990
Ccpyrlght 2009 by
TFF AMFklCAh SUClFTY UF MFCFAhlCAL Fh6lhFFkS
All rlghts reserved
Prlnted ln u.S.A.
C0h1h15
Iorovord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Iroparalion of ToclnicaI Inquirios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Commilloo Roslor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Summary of Clangos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Part 1 5cepe, 0rganizatien, and Intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Part 2 weIded kepairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ArlicIo 2.1 Bull-WoIdod Insorl IIalos in Irossuro Compononls . . . . . . . . . . . . . . . . . . . . . . . . 5
ArlicIo 2.2 IxlornaI WoId OvorIay lo Ropair InlornaI Tlinning . . . . . . . . . . . . . . . . . . . . . . . 11
ArlicIo 2.3 SoaI-WoIdod Tlroadod Connoclions and SoaI WoId Ropairs . . . . . . . . . . . . . . . . 17
ArlicIo 2.4 WoIdod IoaI Box Ropair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ArlicIo 2.5 WoIdod Iip SoaIs (in llo courso of proparalion) . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ArlicIo 2.6 IuII IncircIomonl SlooI Roinforcing SIoovos for Iiping . . . . . . . . . . . . . . . . . . . . . 24
ArlicIo 2.7 IiIIol WoIdod Ialclos Will Roinforcing IIug WoIds . . . . . . . . . . . . . . . . . . . . . . . 31
ArlicIo 2.8 AIlornalivos lo TradilionaI WoIding Iroloal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ArlicIo 2.9 AIlornalivos lo IoslvoId Hoal Troalmonl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ArlicIo 2.10 In-Sorvico WoIding Onlo Carbon SlooI Irossuro Compononls or
IipoIinos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ArlicIo 2.11 WoId BuiIdup, WoId OvorIay, and CIad Rosloralion . . . . . . . . . . . . . . . . . . . . . . . 57
ArlicIo 2.12 IiIIol WoIdod Ialclos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ArlicIo 2.13 Tlroadod or WoIdod IIug Ropairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Part 3 MechanicaI kepairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ArlicIo 3.1 RopIacomonl of Irossuro Compononls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ArlicIo 3.2 Iroozo IIugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
ArlicIo 3.3 Damagod Tlroads in Tappod HoIos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ArlicIo 3.4 IIav Ixcavalion and WoId Ropair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ArlicIo 3.5 IIango Ropair and Convorsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ArlicIo 3.6 MoclanicaI CIamp Ropair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
ArlicIo 3.7 Iipo Slraiglloning or AIignmonl Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ArlicIo 3.8 Damagod Anclors in Concrolo (IoslinslaIIod MoclanicaI Anclors) . . . . . . . . 104
ArlicIo 3.9 VaIvos Will Irossuro-SoaI-Typo Bonnols (in llo courso of proparalion) . . . . . 113
ArlicIo 3.10 Hol BoIling (in llo courso of proparalion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
ArlicIo 3.11 Hol and HaIf BoIling RomovaI Irocoduros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ArlicIo 3.12 Inspoclion and Ropair of SloII and Tubo Hoal Ixclangors . . . . . . . . . . . . . . . . . 119
Part 4 henmetaIIic and ended kepairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
ArlicIo 4.1 NonmolaIIic Composilo Ropair Sysloms for IipoIinos and IipovorI:
Higl-RisI AppIicalions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
ArlicIo 4.2 NonmolaIIic Composilo Ropair Sysloms for IipoIinos and IipovorI:
Iov-RisI AppIicalions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
ArlicIo 4.3 NonmolaIIic InlornaI Iining for Iipo: Sprayod Iorm for Buriod Iipo . . . . . . . 174
Part 5 xaminatien and 1esting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
ArlicIo 5.1 Irossuro and Tigllnoss Tosling of Iiping and Iquipmonl . . . . . . . . . . . . . . . . . . 186
ArlicIo 5.2 Nondoslruclivo Ixaminalion in Iiou of Irossuro Tosling for Ropairs
and AIloralions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
iii
F0kw0k
ASMI formod an Ad Hoc TasI Group on Iosl Conslruclion in 1993 in rosponso lo an incroasod
nood for rocognizod and gonoraIIy accoplod onginooring slandards for llo inspoclion and mainlo-
nanco of prossuro oquipmonl aflor il las boon pIacod in sorvico. Al llo rocommondalion of llis
TasI Group, llo Board on Irossuro ToclnoIogy Codos and Slandards (BITCS) formod llo Iosl
Conslruclion Commilloo (ICC) in 1995. Tlo scopo of llis commilloo vas lo dovoIop and mainlain
slandards addrossing common issuos and loclnoIogios roIalod lo posl-conslruclion aclivilios and
lo vorI vill ollor consonsus commilloos in llo dovoIopmonl of soparalo, producl-spocific codos
and slandards addrossing issuos oncounlorod aflor iniliaI conslruclion for oquipmonl and piping
covorod by Irossuro ToclnoIogy Codos and Slandards. Tlo BITCS covors non-nucIoar boiIors,
prossuro vossoIs (incIuding loal oxclangors), piping and piping compononls, pipoIinos, and
slorago lanIs.
Tlo ICC soIocls slandards lo bo dovoIopod basod on idonlifiod noods and llo avaiIabiIily of
voIunloors. Tlo ICC formod llo Subcommilloo on Inspoclion IIanning and llo Subcommilloo
on IIav IvaIualions in 1995. In 1998, a TasI Group undor llo ICC bogan proparing GuidoIinos
for Irossuro Boundary BoIlod IIango }oinl AssombIy. In 1999, llo ICC formod llo Subcommilloo
on Ropair and Tosling. In 2002, llo Subcommilloo on IIavIvaIualion vas dissoIvod, and ropIacod
by llo }oinl ASMI/AII Commilloo on Iilnoss for Sorvico. Ollor lopics aro undor considoralion
and may bo dovoIopod inlo fuluro guidoIino documonls.
Tlo subcommilloos voro clargod vill proparing slandards doaIing vill sovoraI aspocls of llo
in-sorvico inspoclion and mainlonanco of prossuro oquipmonl and piping. Tlo Inspoclion IIanning
Slandard providos guidanco on llo proparalion of a risI-basod inspoclion pIan. Dofocls llal aro
idonlifiod aro llon ovaIualod, vlon approprialo, using llo procoduros providod in llo Iilnoss
for Sorvico. IinaIIy, if il is dolorminod llal ropairs aro roquirod, guidanco on ropair procoduros
is providod in llo Ropair of Irossuro Iquipmonl and Iiping Slandard. Tloso documonls aro in
various slagos of proparalion.
Nono of lloso documonls aro Codos. Tloy provido rocognizod and gonoraIIy accoplod good
praclicos llal may bo usod in conjunclion vill Iosl-Conslruclion Codos, sucl as AII 510, AII 570,
and NB-23, and vill jurisdiclionaI roquiromonls.
Tlo firsl odilion of ASMI ICC-1, ,
vas approvod for pubIicalion in 2000. ASMI ICC-1-2000 vas approvod by llo Amorican NalionaI
Slandards Inslilulo (ANSI) as an Amorican NalionaI Slandard on Novombor 15, 2000.
Tlo firsl odilion of ASMI ICC-2, , vas approvod for
pubIicalion in 2004. Tlis rovision vas approvod by ANSI as an Amorican NalionaI Slandard on
Soplombor 25, 2008.
iv
PkPAkA1I0h 0F 1ChhICAL IhbIkI5
Ih1k0bC1I0h
Tlo ASMI Iosl-Conslruclion Slandards Commilloo viII considor vrillon roquosls for inlorpro-
lalions and rovisions of llo ruIos of llis Slandard and dovoIop nov ruIos if diclalod by loclnoIogi-
caI dovoIopmonl. Tlo Commilloos aclivilios in llis rogard aro Iimilod slriclIy lo inlorprolalions
of llo ruIos or lo llo considoralion of rovisions lo llo prosonl ruIos on llo basis of nov dala or
loclnoIogy. As a mallor of pubIislod poIicy, ASMI doos nol approvo, corlify, ralo, or
ondorso any ilom, conslruclion, propriolary dovico, or aclivily, and, accordingIy, inquirios
roquiring sucl considoralion viII bo rolurnod. Moroovor, ASMI doos nol acl as a consuIlanl on
spocific onginooring probIoms or on llo gonoraI appIicalion or undorslanding of llo ruIos. If,
basod on llo inquiry informalion submillod, il is llo opinion of llo Commilloo llal llo inquiror
slouId sooI profossionaI assislanco, llo inquiry viII bo rolurnod vill llo rocommondalion llal
sucl assislanco bo oblainod.
An inquiry llal doos nol provido llo informalion noodod for llo Commilloos fuII undorslanding
viII bo rolurnod.
kbIkMh15
Inquirios slaII bo Iimilod slriclIy lo inlorprolalions of llo ruIos or lo llo considoralion of
rovisions lo llo prosonl ruIos on llo basis of nov dala or loclnoIogy. Inquirios slaII mool llo
foIIoving roquiromonls:
InvoIvo a singIo ruIo or cIosoIy roIalod ruIos in llo scopo of llo slandard. An inquiry
Iollor concorning unroIalod subjocls viII bo rolurnod.
Slalo llo purposo of llo inquiry, vlicl may bo oillor lo oblain an inlorprolalion
of ruIos of llis Slandard, or lo proposo considoralion of a rovision lo llo prosonl ruIos. Irovido
concisoIy llo informalion noodod for llo Commilloos undorslanding of llo inquiry, boing suro
lo incIudo roforonco lo llo appIicabIo Iarl, ArlicIo, Idilion, Addonda, paragrapls, figuros, and
labIos. If sIolclos aro providod, lloy slaII bo Iimilod lo llo scopo of llo inquiry.

Tlo inquiry slaII bo slalod in condonsod and prociso quoslion for-
mal, omilling suporfIuous bacIground informalion, and, vloro approprialo, composod in sucl
a vay llal yos or no (porlaps vill provisos) vouId bo an accoplabIo ropIy. Tlo inquiry
slalomonl slouId bo loclnicaIIy and odiloriaIIy corrocl.
Irovido a proposod ropIy slaling vlal llo inquiror boIiovos llal llo
slandard roquiros.
If in llo inquirors opinion, a rovision lo llo slandard is noodod, rocommondod vording slaII
bo providod in addilion lo informalion juslifying llo clango.
5bMI11AL
Inquirios slaII bo submillod in lypovrillon form, lovovor, IogibIo landvrillon inquirios viII
bo considorod. Tloy slaII incIudo llo namo and maiIing addross of llo inquiror, and may oillor
bo sonl by omaiI lo SocrolaryICCasmo.org, or by maiI lo llo foIIoving addross:
Socrolary
ASMI Iosl Conslruclion
Tlroo IarI Avonuo
Nov YorI, NY 10016-5990
v
A5M Pk55bk 1Chh0L0C
P051 C0h51kbC1I0h C0MMI11
(The fcllcwlng ls the rcster cf the Ccmmlttee at the tlme cf apprcval cf thls Standard.)
51AhAk5 C0MMI11 0FFICk5
. A. Lang, 5r.,
[. k. 5ims, [r.,
5. [. kessi,
51AhAk5 C0MMI11 Pk50hhL
C. A. Antaki, 8echt Fnglneerlng Cc., lnc.
[. . atey, The ucw Chemlcal Cc.
C. echt Iv, 8echt Fnglneerlng Cc., lnc.
. L. erger, PPL 6eneratlcn LLC
P. h. Chaku, A88 Lummus 6lcbal, lnc.
C. . CewIer, Ccnsultant
P. C. hackIerd, utah Labcr Ccmmlsslcn
w. [. keves, uUP LLC
. A. Lang, 5r., FM 6lcbal
C. k. Leenard, Llfe Cycle Fnglneerlng
. MichaIepeuIes, Clty cf Kcnzal, 6reece
kPAIk Ah 151IhC 5bC0MMI11 (PCC)
C. echt Iv, 8echt Fnglneerlng Cc., lnc.
C. . kedery, 8P hcrth Amerlcan Prcducts, lnc.
5. [. kessi, The Amerlcan Scclety cf Mechanlcal
Fnglneers
C. A. Antaki, 8echt Fnglneerlng Cc., lnc.
L. P. AntaIIIy, Flucr uanlel
M. A. ering, Fdlscn weldlng lnstltute
[. A. rewn, AkFvA hP
P. h. Chaku, A88 Lummus 6lcbal, lnc.
h. [. ammeyer, The Uhlc State unlverslty
h. . Faransse, K8k
5. [. FindIan, FPkl kkAC
. F. hantz, FxxcnMcbll kesearch and Fnglneerlng Cc.
C. k. harIey, 6eneral Physlcs Ccrp.
w. F. hart, Furmanlte Amerlca, lnc.
vi
k. Mekhtarian, Ccnsultant
C. C. heeIy, 8echt Fnglneerlng Cc., lnc.
1. M. Parks, The hatlcnal 8card cf 8cller and Pressure vessel
lnspectcrs
[. 1. keyneIds, Ccnsultant
5. C. keberts, Shell 6lcbal Sclutlcns uS, lnc.
C. . kedery, 8P hcrth Amerlcan Prcducts, lnc.
5. [. kessi, The Amerlcan Scclety cf Mechanlcal Fnglneers
C. w. kewIey, The wesley Ccrp.
M. . C. 5chmidt, Ccnsultant
[. k. 5ims, [r., 8echt Fnglneerlng Cc., lnc.
. . kadakia, T. u. wllllamscn, lnc.
w. [. keves, uUP LLC
k. Mekhtarian, Ccnsultant
w. F. heweII, [r., w. F. hewell & Asscclates, lnc.
1. M. Parks, The hatlcnal 8card cf 8cller and Pressure vessel
lnspectcrs
[. 1. keyneIds, Ccnsultant
5. C. keberts, Shell 6lcbal Sclutlcns uS, lnc.
C. w. kewIey, The wesley Ccrp.
5. C. 5hah, FxxcnMcbll kesearch and Fnglneerlng Cc.
. . 5tewart, Kansas Clty ueaeratcr Cc.
[. 1aagepera, Chevrcn Fnergy Technclcgy Cc.
1. 1ahara, T & T Technclcgy
. bpitis, upltls & Asscclates, lnc.
k. h. waIker, Cltadel Technclcgles
A5M PCC-22008
5bMMAk 0F ChAhC5
IoIIoving approvaI by llo ASMI Iosl Conslruclion Commilloo and ASMI, and aflor pubIic
roviov, ASMI ICC-22008 vas approvod by llo Amorican NalionaI Slandards Inslilulo on
Soplombor 25, 2008.
ASMI ICC-22008 incIudos odiloriaI clangos, rovisions, and corroclions inlroducod in ASMI
ICC-22006, as voII as llo foIIoving clangos idonlifiod by a margin nolo, .

2 TabIo 1 Rovisod
11 ArlicIo 2.2 TilIo rovisod
31 ArlicIo 2.7 Addod
74 ArlicIo 3.2 (1) Iaragrapl 2.7 doIolod, and paras. 2.8
llrougl 2.10 rodosignalod as 2.7
llrougl 2.9, rospoclivoIy
(2) Iaragrapl 3.1 rovisod in ils onliroly
80 ArlicIo 3.3 Roforoncos in soclion 7 updalod
84, 85 ArlicIo 3.3, Mandalory (1) In para. II-1.1, nomoncIaluro for
Appondix II corroclod lo road
by orrala
(2) In para. II-1.2, ASMI B1.1 roforonco in
Nolo updalod
(3) TilIo of para. II-1.2.1 rovisod
94, 95 ArlicIo 3.5 (1) Iaragrapl 2.2 rovisod
(2) Iaragrapl 3.1 rovisod
(4) Nov para. 4.5 addod
131142 ArlicIo 4.1 (1) TilIo rovisod
(2) In 1.1, subpara. (g) addod
(3) Iaragrapl 2.1 lilIo rovisod
(4) In 3.1,
dofocl
addod
(5) In 3.3.3, subpara. (o) addod
(6) In 3.4.2, Iasl paragrapl rovisod and
nov oqs. (1) and (2) addod
(7) TabIo 2 lilIo rovisod
vii

(8) In 3.4.3, sixll paragrapl rovisod
(9) TabIos 4 llrougl 7 rodosignalod as
TabIos 3 llrougl 6, rospoclivoIy, and
provious TabIo 3 doIolod
(10) In 3.4.5, Iasl paragrapl rovisod
(11) In 5.3, firsl paragrapl rovisod
148 ArlicIo 4.1, Mandalory In II-3, subpara. (c) addod
Appondix II
150 ArlicIo 4.1, Mandalory In III-2, socond and llird paragrapls
Appondix III rovisod
153 ArlicIo 4.1, Mandalory (1) In V-2.1, nov llird paragrapl addod
Appondix V (2) Nov oq. (V-2) addod
156 ArlicIo 4.1, Mandalory In VII-1, Iasl sonlonco of firsl paragrapl
Appondix VII rovisod
157 ArlicIo 4.1, Mandalory (1) In VIII-3, subpara. (c) rovisod
Appondix VIII (2) In VIII-4, firsl llroo paragrapls
rovisod
(3) In VIII-5, subpara. (b)(2) rovisod
158 ArlicIo 4.1, Mandalory In IX-1, lorm addod
Appondix IX
161166 ArlicIo 4.2 (1) TilIo rovisod
(4) In 1.4, firsl sonlonco rovisod
(8) In 3.1, dofinilion for rovisod, symboI
corroclod lo road
, and dofinilions
for
dofocl
,
, and
addod
(12) TabIo 1 rovisod
(13) In TabIo 2, undor MaloriaIs
proparalion, rosin ropIacod vill
poIymor
(18) Soclion 6 rovisod in ils onliroly
(19) In TabIo 3, onlry for Inlorfaco
rovisod, aII roforoncos lo rosin
ropIacod vill poIymor
(20) Roforoncos in soclion 7 updalod
169 ArlicIo 4.2, Mandalory (1) Iaragrapl II-1 rovisod in ils onliroly
Appondix II (2) In II-2, subparas. (a), (b), and (d)
rovisod
(3) Iaragrapl II-3 rovisod in ils onliroly
viii

170 ArlicIo 4.2, Mandalory (1) Iaragrapl III-1 rovisod in ils onliroly
Appondix III (2) Iaragrapl III-2 rovisod in ils onliroly
171 ArlicIo 4.2, Mandalory (1) Iaragrapl IV-1 rovisod in ils onliroly
Appondix IV (2) Iaragrapl IV-2.3 rovisod in ils onliroly
172 ArlicIo 4.2, Mandalory (1) Iaragrapl V-1 rovisod in ils onliroly
Appondix V (2) Iaragrapl V-2 rovisod in ils onliroly
(3) In para. V-3(c), lorm rosin ropIacod
vill poIymor
(4) Iaragrapl V-4 rovisod in ils onliroly
(5) Iaragrapl V-5(b)(2) rovisod
173 ArlicIo 4.2, Mandalory (1) In VI-1, lorm addod
Appondix VI (2) Dofinilions for and
rovisod
(3) Torm rovisod lo road

(4) Torm rovisod lo road

174 ArlicIo 4.3 Rovisod in ils onliroly
183 ArlicIo 4.3, Mandalory Rovisod in ils onliroly
Appondix II
185 ArlicIo 4.3, Mandalory (1) In III-1, dofinilions for
Appondix III
and rovisod
(2) AIso in III-1, lorm addod and
lorms and
rovisod lo road and
, rospoclivoIy
(3) Iaragrapl III-2 updalod
186 ArlicIo 5.1 Rovisod in ils onliroly
ix
lhTFhTlUhALLY LFFT 8LAhK
x

51AhAk F0k 1h kPAIk 0F Pk55bk
bIPMh1 Ah PIPIhC
PAk1 1
5C0P, 0kCAhIZA1I0h, Ah Ih1h1
1 5C0P
Tlis Slandard providos mollods for ropair of oquip-
monl and piping villin llo scopo of ASMI Irossuro
ToclnoIogy Codos and Slandards
1
aflor il las boon
pIacod in sorvico. Tloso ropair mollods incIudo roIovanl
dosign, fabricalion, oxaminalion, and losling praclicos
and may bo lomporary or pormanonl, doponding on llo
circumslancos.
Tlo mollods providod in llis Slandard addross llo
ropair of compononls vlon ropair is doomod nocossary
basod on approprialo inspoclion and fIav assossmonl.
Tloso inspoclion and fIav ovaIualion mollods aro nol
covorod in llis documonl, bul aro covorod in ollor posl-
conslruclion codos and slandards.
OnIy loclnicaI procoduros and informalion aro pro-
vidod, adminislralivo or poIicy roquiromonls aro oulsido
of llo scopo of llis Slandard.
2 0kCAhIZA1I0h
Tlis Slandard is dividod inlo fivo Iarls.
Iarl 1 covors llo scopo, organizalion, and inlonl
and is appIicabIo lo aII arlicIos in llis Slandard. TabIo 1
providos guidanco for llo appIicabiIily of ropair moll-
ods Iislod in llis Slandard.
Iarl 2 covors ropair mollods and loclniquos llal
incIudo llo uso of voIding, brazing, soIdoring, or ollor
mollods invoIving molaI doposil.
Iarl 3 covors moclanicaI ropairs, vill or villoul
soaIanl, sucl as boIlod cIamps or fixluros and incIudos
aII ropair mollods nol covorod in Iarl 2 or Iarl 4.
Iarl 4 covors ropairs using nonmolaIIic moans,
sucl as nonmolaIIic Iinors and vraps, and bonding (o.g.,
j oining by opoxy), incIuding bonding of molaIIic
compononls.
1
Iquipmonl and piping villin llo scopo of ASMI Irossuro
ToclnoIogy Codos and Slandards incIudos piping (incIuding pipo-
Iinos) and piping compononls (sucl as vaIvos), boiIors, prossuro
vossoIs (incIuding loal oxclangors), and slorago lanIs.
1
Iarl 5 covors oxaminalion and losling mollods
and loclniquos.
3 Ih1h1
3.1 CeneraI
Tlis Slandard providos loclnicaI informalion, proco-
duros, and rocommondalions for ropair mollods llal
voro dolorminod by consonsus lo bo rocognizod and
gonoraIIy accoplod good onginooring praclico. Wloro
oquipmonl ropair is subjocl lo jurisdiclionaI roguIalion,
jurisdiclionaI approvaIs may bo roquirod.
3.2 eIinitiens
Tlo vords , , and aro usod in llo ropair
arlicIos of ICC-2 and lloy lavo llo foIIoving inlonl:
indicalos an aclion llal is pormillod, bul nol
roquirod.
an aclion llal is mandalory. Il indicalos an aclion
llal is an ossonliaI oIomonl of llo ropair mollod llal
cannol bo oIiminalod.
an aclion llal is nol mandalory. Il indicalos an
aclion llal vlon porformod, is gonoraIIy considorod lo
bo good praclico, lovovor, lloro aro somo circumslancos
vlon llo aclion is nol approprialo or roquirod, so llo
vord is usod lo provido fIoxibiIily for llo arlicIo lo
covor a broad rango of circumslancos. Il is nol mandalory
unIoss so spocifiod by ollors in llo appIicalion of lloso
arlicIos.
3.3 Administrative kequirements
Ior adminislralivo roquiromonls sucl as inspoclion,
documonlalion, and quaIily conlroI, llo usor is roforrod
lo an appIicabIo posl-conslruclion codo and lo llo juris-
diclionaI roquiromonls. In llo absonco of an appIicabIo
posl-conslruclion codo or jurisdiclionaI roquiromonls,
llo ovnor of llo prossuro oquipmonl or piping slouId

2

3

oslabIisl llo adminislralivo roquiromonls. A posl-
conslruclion codo is ono llal providos roquiromonls and
guidanco for inspoclion and/or ropair of oquipmonl
aflor il las boon pIacod in sorvico, and may incIudo llo
roforoncos lo originaI codo of conslruclion. IxampIos of
posl-conslruclion codos incIudo NB-23, AII 510,
AII 570, and AII 653.
3.4 AppIicatien
Usors of llo arlicIos conlainod in llis documonl aro
caulionod llal lloso arlicIos lavo boon dovoIopod gonor-
icaIIy and aro rocommondod for gonoraI appIicalions.
Tloy may nol nocossariIy bo suilabIo for aII appIicalions.
Irocaulionary considoralions aro providod, bul slouId
nol bo considorod aII incIusivo. Sound onginooring prac-
licos and judgmonl slouId bo usod lo dolormino llo
appIicabiIily of a spocific mollod or parl of a mollod
lo a spocific appIicalion. Iacl ropair slouId bo subjocl
lo an approprialo roviov by quaIifiod porsonnoI, and
llis roviov slouId considor subsoquonl dolorioralion of
llo ropairod compononl.
Somo Iimilalions and considoralions aro conlainod in
soclion 2 of llo individuaI arlicIos.
3.5 AIternative bse
WliIo llis Slandardcovors ropair of oquipmonl villin
llo scopo of ASMI Irossuro ToclnoIogy Codos and
Slandards, il may bo usod on oquipmonl conslruclod in
accordanco vill ollor Codos and Slandards.
3.6 ArticIes' Independence
IndividuaI arlicIos in llis Slandard may bo usod indo-
pondonlIy of ollor arlicIos, oxcopl vlon ollorviso
nolod. Hovovor, llis Iarl (Iarl 1) appIios lo aII arlicIos
in llis Slandard.
3.7 kepair LiIe
Many of llo ropair loclniquos incI udod in llis
Slandard aro considorod lo bo pormanonl, inlondod lo
romain in pIaco for llo Iifo of llo ropairod compononl.
Ollors may onIy bo suilabIo for slorl-lorm sorvico, and
slouId bo ropIacod vill a moro pormanonl ropair al
llo approprialo opporlunily. Tlo anlicipalod Iifo of llo
ropair doponds on many circumslancos, and couId
incIudo considoralion of risI. As sucl, llis Slandard
doos nol cIassify ropair mollods as pormanonl or lompo-
rary. Rallor, loclnicaI considoralions llal affocl llo
4
oxpoclod Iifo of llo ropair aro slalod in llo individuaI
arlicIos.
3.8 Cede keIerences
Roforonco lo spocific codos is gonoraIIy avoidod in llis
Slandard bocauso llo oquipmonl or piping couId lavo
boon conslruclod in accordanco vill a numbor of diffor-
onl codos. Wloro sucl a roforonco is providod, il is gonor-
aIIy llo inlonl lo incIudo, by roforonco, a spocific
loclnicaI provision.
3.9 weIding
Roquiromonls for voIding, incIuding quaIificalion of
voIding procoduros, voIdors, and voIding oporalors,
slouId gonoraIIy foIIov an appIicabIo codo of conslruc-
lion or an appIicabIo posl-conslruclion codo, oxcopl
vlon ollorviso spocifiod loroin.
3.10 AIIewabIe 5tress
CaIcuIalions invoIving llo aIIovabIo slross uso llo
aIIovabIo slross fromllo originaI codo of conslruclion or
an appIicabIo posl-conslruclion codo, unIoss ollorviso
spocifiod in spocific arlicIos.
3.11 xaminatien
Wlon quaIificalions of oxaminors, mollods of oxami-
nalion, oxlonl of oxaminalion, and accoplanco criloria
aro nol spocifiod, lloy slouId foIIov llo roquiromonls
of an appIicabIo codo of conslruclion or an appIicabIo
posl-conslruclion codo.
3.12 kecerds
Tlo ovnor slouId Ioop rocords llal documonl llo
ropair. Spocific roquiromonls for documonlalion aro nol
providod in llis Slandard. Tlo ovnor slouId rolain roc-
ords llal compIy vill appIicabIo jurisdiclionaI and
posl-conslruclion codo roquiromonls. Documonlalion
may incIudo sucl iloms as a doscriplion of llo condilion
llal roquirod allonlion and ils causo, ropair procoduros
llal voro usod, plolos prior lo and aflor llo ropair,
oxaminalion procoduros and rocords, loal lroalmonl roc-
ords, losl rocords, and llo namos of llo porsons/firms
porforming llo ropair and oxaminalion and lloir corlifi-
calion. Tlo documonlalion forms parl of llo lislory of
llo prossuro compononl and slouId bo rolainod as Iong
as il is roIovanl.

PAk1 2
wL kPAIk5
ArticIe 2.1
utt-weIded Insert PIates in Pressure Cempenents
1 5CkIP1I0h
1.1 CeneraI Censideratiens
Tlo ropair of prossuro compononls by bull-voIdod
insorl pIalos invoIvos llo ropIacomonl of prossuro
boundary maloriaI in a prossuro compononl vill an
insorl pIalo allaclod by fuII ponolralion bull voIds. Tlis
ropair mollod is appIicabIo lo cyIindricaI, sploricaI, and
conicaI sloIIs and lo fIal prossuro compononls. Il may
bo usod for singIo and doubIo curvaluro sloIIs. Il may
aIso bo usod on ollor prossuro compononls (sucl as
formod loads) if llo curvaluro of llo ropIacod soclion
malclos llo curvaluro of llo originaI prossuro parl. Il
is nol Iimilod by llo sizo of llo prossuro compononl,
oxcopl vloro praclicaI considoralions procIudo llo uso
of an insorl, sucl as on smaII diamolor pipo or lubo. Il
may bo usod on smaII diamolor prossuro compononls if
spociaI caro is laIon lo onsuro a cIoso fil of llo insorl
pIalo and llo oxisling prossuro compononl and llal llo
ropairod prossuro compononl mools llo loIoranco
roquiromonls of llo appIicabIo codo of conslruclion.
1.2 kepIacement eI LecaI Areas in Pressure vesseI
5heIIs er Pipe waIIs
Tlis ropair mollod is inlondod lo bo usod lo ropIaco
porlions of prossuro-rolaining vossoI sloIIs or pipo vaIIs
llal lavo boon damagod by cracIs, IocaI vaII llinning
from orosion, corrosion, and ollor damago moclanisms.
Tlo insorl pIalo may conlain ono or moro nozzIos/
manvays.
1.3 kepIacement eI ntire Cempenent
RopIacomonl of an onliro compononl, sloII pIalo, or a
compIolo sloII courso of a cyIindricaI sloII, or a compIolo
circuIar sogmonl of a sploro, or a compIolo load, or a
soclion of a pipo is nol considorod in llis ropair mollod.
5
2 LIMI1A1I0h5
2.1 Part 1 eI 1his 5tandard
Iarl 1 of llis Slandard conlains addilionaI roquiro-
monls and Iimilalions. Tlis ArlicIo slaII bo usod in con-
junclion vill Iarl 1.
2.2 AdditienaI Censideratiens and Limitatiens
Wlon appIying llis ropair mollod, considoralion
slaII bo givon lo compalibiIily of maloriaIs, oporaling
condilions for llo inlondod Iifo of llo compononl, filling
and voIding lo minimizo llo rosiduaI slrossos and dis-
lorlions, and any Iimilalions on nondoslruclivo oxami-
nalion and prossuro losling.
2.3 Leadings
Tlis mollod may bo usod for oquipmonl subjocl lo
oillor inlornaI or oxlornaI prossuro. If llo prossuro com-
pononl is subjocl lo oxlornaI prossuro, addilionaI consid-
oralion slaII aIso bo givon lo any Ioss of bucIIing
slrongll as a rosuIl of pormanonl dislorlions or misaIign-
monl in llo ropairod compononl. If llo prossuro compo-
nonl is subjocl lo cycIic Ioading, addilionaI considoralion
slaII bo givon lo llo offocl of pormanonl dislorlions on
llo faliguo Iifo of llo ropairod compononl.
2.4 Cerresien-kesistant weId 0verIay er CIadding
Tlis ropair mollod may aIso bo usod in vossoIs llal
aro oillor cIad vill corrosion-rosislanl Iining or voId
ovorIay. Tlo insorl pIalo cIadding or voId ovorIay slaII
bo compalibIo vill llo oxisling maloriaIs and suilabIo
for llo inlondod sorvico. Considoralion slaII aIso bo
givon lo llo uso of voId dolaiIs and voIding procoduros
suilabIo for llo inlondod sorvico.
2.5 issimiIar MetaIs
Uso of dissimiIar maloriaIs (baso molaI and voIds) is
nol prolibilod, bul llo maloriaIs slaII mool llo roquirod
minimum moclanicaI proporlios for llo prossuro com-
pononl and slaII bo carofuIIy ovaIualod for compalibiIily

bolvoon llo dissimiIar maloriaIs and llo sorvico onvi-
ronmonl, boll inlornaI and oxlornaI. If llormaI faliguo
is a possibiIily, considoralion slaII bo givon lo llo polon-
liaI for accoIoralod faliguo cracIing in llo dissimiIar
molaIs combinalion.
3 5ICh
3.1 Cede eI Censtructien
Tlo insorl pIalo llicInoss, maloriaI, and voIds slaII
mool llo dosign roquiromonls in llo appIicabIo codo of
conslruclion for llo oxisling prossuro compononl inlo
vlicl il is boing inslaIIod and slaII bo consislonl vill
llo joinl officioncy or joinl quaIily faclors usod in llo
originaI dosign, oxcopl as pormillod in para. 3.3. Tlo
aIIovabIo slrossos slaII bo llo samo as in llo appIicabIo
codo of conslruclion for llo oxisling compononl.
3.2 MateriaIs
Insorl pIalos and voIds slouId bo of llo samo maloriaI
as llo oxisling prossuro compononl, or of anollor malo-
riaI llal las al Ioasl oquaI nolcl louglnoss and aIIovabIo
slross, conforms lo llo roquiromonls of llo appIicabIo
codo of conslruclion, and is suilabIo for llo inlondod
sorvico. Wloro ASMI maloriaIs aro usod, llo ropIaco-
monl maloriaI slouId lavo llo samo ASMI I-Numbor
dosignalion as llo prossuro compononl maloriaI inlo
vlicl llo insorl is boing inslaIIod.
3.3 Insert PIate 1hickness
Tlo insorl pIalo llicInoss slouId bo nol Ioss llan llo
nominaI llicInoss of llo maloriaI il voIds inlo. If a
llinnor insorl pIalo llan llo nominaI llicInoss of llo
maloriaI il voIds inlo musl bo usod, il slaII bo ovaIualod
for llo inlondod sorvico (sucl as faliguo duo lo cycIic
Ioading) using llo ruIos in llo appIicabIo codo of con-
slruclion for llo prossuro compononl, or llo appIicabIo
posl-conslruclion codo. Soo para. 4.1.5.
3.4 kectanguIar and 5quare Insert PIates
RoclanguIar and squaro insorl pIalos slaII lavo cor-
nors roundod lo a radius, oxcopl vlon llo onliro sloII
pIalo is ropIacod. RoclanguIar and squaro insorl pIalos
13 mm (
1
2
in.) llicI and up lo and incIuding 25 mm
(1 in.) llicI slouId lavo a 75 mm (3 in.) or a Iargor
cornor radius. Insorl pIalos Ioss llan 13 mm (
1
2
in.) llicI
may lavo smaIIor cornor radii. Insorl pIalos ovor 25 mm
(1 in.) llicI slouId lavo a 150 mm (6 in.) or a Iargor
cornor radius.
3.5 FIush Inserts
IIusl insorls in pipo or lubo may bo round or obIong
culouls, as slovn in Iig. 1, or roclanguIar culouls vill
roundod cornors.
6
Fig. 1 FIush Insert in Pipe er 1ube

hUTFS:
(1) Slde vlew cf cutcut ln plpe cr tube wlth edge bevels. (Flg. 1
shcws slngle-grccved |clnt detall wlth 25 deg tc 35 deg edge
bevel ln plpe cr tube. Uther |clnt detalls and edge bevels may
be used, as apprcprlate fcr a partlcular weld |clnt.)
(2) Plan vlew cf lnsert wlth edge bevels. (Flg. 1 shcws an lnsert
wlth cne-slded |clnt detall.)
(3) Slde vlew cf the lnsert wlth edge bevels. (Uther |clnt detalls
and edge bevels may be used, as apprcprlate fcr a partlcular
weld |clnt.)
(/) Slde vlew cf welded lnsert ln plpe cr tube.
3.6 Insert PIate 5ize
Tlo insorl pIalo slaII bo of sufficionl sizo lo ropIaco
llo onliro aroa of llo oxisling prossuro compononl llal
las boon assossod as nol boing fil for conlinuod opora-
lion and lo onsuro llal aII voIds aro in sound maloriaI.
3.6.1 Minimum 5ize eI Insert PIates. Tlo minimum
diamolor, or Iongll and vidll dimonsions of non-posl-
voId loal-lroalod, bull-voIdod carbon and Iov aIIoy
slooI insorl pIalos slaII bo llo Iossor of 12 or 380 mm
(15 in.) (vloro is llo llicInoss of llo paronl maloriaI).
Soo para. 3.8.

3.7 5tructuraI 5tabiIity at Cuteuts
Considoralion slouId bo givon lo slrucluraI slabiIily
and possibIo dislorlion of llo unsupporlod pIalo odgos
of Iargo oponings (culouls) in llo vossoI sloII. An assoss-
monl slouId bo mado for llo nood of lomporary sup-
porls around llo unsupporlod odgos of sucl oponings
during romovaI of llo sloII soclion lo bo ropIacod vill
an insorl pIalo. Tlo assossmonl slaII considor aII Ioading
condilions llal may occur on llo vossoI and llo compo-
nonl during llo ropair, incIuding slrucluraI slabiIily of
vossoIs during IWHT.
3.8 Insert PIates with hezzIes
Tlo nozzIo/manvay roinforcomonl in insorl pIalos
vill nozzIos slaII mool llo dosign roquiromonls and
voIddolaiIs of llo appIicabIo codo of conslruclionfor llo
prossuro compononl. Tlo minimum diamolor of insorl
pIalo vill a nozzIo slaII bo llo Iargor of llo foIIoving:
for aII nozzIo/manvay assombIios, llo diamolor
of llo nozzIo/manvay ponolralion pIus llo vidll
noodod for nozzIo roinforcomonl and any odgo bovoIs
for non-poslvoId loal-lroalod carbon and Iov
aIIoy slooI nozzIo/manvay assombIios, llo diamolor of
llo insorl pIalo noodod lo mainlain a minimum dislanco
of 150 mm (6 in.) bolvoon llo nozzIo allaclmonl voId
and llo noarosl odgo of llo insorl pIalo bull voId. Hov-
ovor, llo diamolor of llo insorl pIalo for nozzIos laving
an oulsido diamolor 300 mm (12 in.) or smaIIor nood
nol bo Iargor llan 2 limos llo oulsido diamolor of llo
nozzIo. (Soo aIso Iigs. 2 and 3.)
4 FAkICA1I0h
4.1 Cutting and Ferming
4.1.1 dge eveIs. Idgo bovoIs in llo insorl pIalo
and in llo prossuro compononl may bo proparod by
llormaI culling, arc gouging, maclining, or grinding.
Tlo mollod slouId bo approprialo for llo maloriaI and
voIding procoss(os) usod.
AII odgos proparod for voIding slaII bo oxaminod lo
llo roquiromonls of llo appIicabIo codo of conslruclion
or posl-conslruclion codo for llo prossuro compononl
boing ropairod. AII unaccoplabIo indicalions slaII bo
ropairod lo llo roquiromonls of llo appIicabIo codo of
conslruclion or posl-conslruclion codo.
4.1.2 Ferming. Iorming llo insorl pIalo lo llo
dosirod slapo may bo accompIislod by any procoss llal
doos nol impair llo proporlios of llo pIalo maloriaI. Il
may bo roIIod or prossod lo llo propor curvaluro sucl
llal il conforms lo llo curvaluro of llo vossoI sloII aflor
il las boon inslaIIod and voIdod inlo llo vossoI sloII,
pipo, or lubo. Ior pipo or lubo insorls, llo insorl may
aIso bo cul from anollor pioco of pipo or lubo of llo
samo diamolor and llicInoss as llo pipo or lubo lo
7
Fig. 2 FIush Insert PIate (with er witheut
hezzIe]Manway) with Its utt weId Intersecting
xisting utt weId in 5heIIs er heads

hUTFS:
(1) Fxlstlng butt weld ln vessel shell cr head. (Flg. 2 shcws butt
weld ln a cyllndrlcal shell.)
(2) Thlrty deg mlnlmum angle.
(3) Full kT cr uT, cr MT cr PT bcth sldes cf exlstlng butt weld,
100 mm (/ ln.) mln. each slde cf lntersectlcn wlth lnsert plate.
(/) lnsert plate butt weld. Full kT cr uT, cr MT cr PT bcth sldes cf
weld.
(5) Fcr ncnpcstweld heat-treated carbcn and lcw allcy steel
nczzle]manway assemblles, 150 mm (6 ln.) mlnlmum between
the tce cf the nczzle flllet weld and the nearest edge cf the
lnsert plate butt weld (see para. 3.8).
bo ropairod. TlicIor pipo or lubo insorls may bo usod,
providod lloy mool llo roquiromonls of para. 4.1.5.
4.1.3 Ferming 5trains in Carben and Lew AIIey
5teeIs. Carbon slooI and Iov aIIoy slooI insorl pIalos
slouId bo loal lroalod (slross roIiovod, normaIizod, or
quonclod and lomporod, if approprialo) subsoquonlIy
vlon llo rosuIling oxlromo fibor oIongalion during coId
forming is moro llan 5, as dolorminod by llo foIIoving
formuIas:
Ior singIo curvaluro sloIIs (cyIindors)
Iorconl oxlromo fibor oIongalion
75
,
Ior doubIo curvaluro (loads and sploricaI sloIIs),
Iorconl oxlromo fibor oIongalion
50
,
vloro
finaI conlorIino radius, mm (in.)


Fig. 3 Intersecting "egheuse" 1ype Insert PIate
utt weId (with er witheut hezzIe]Manway)
with 5heII utt weId in vesseI 5heIIs and heads

hUTFS:
(1) Fxlstlng butt weld ln vessel shell cr head. (Flg. 3 shcws butt
weld ln a cyllndrlcal shell.)
(2) Length cf cut ln shell butt weld, 150 mm (6 ln.) mlnlmum cn
each slde cf lntersectlng lnsert plate butt weld.
(3) lnsert plate butt weld.
(/) Cut exlstlng shell butt weld tc 150 mm (6 ln.) mlnlmum cn
each slde cf lntersectlng lnsert plate butt weld and bevel
edges (cr arc gcuge edges) tc the deslred edge bevels. keweld
after ccmpletlcn cf lnsert plate butt weld. Full kT cr uT, cr MT
cr PT bcth sldes cf new weld.
(5) Fcr ncnpcstweld heat-treated carbcn and lcw allcy steel
nczzle]manway assemblles, 150 mm (6 ln.) mlnlmum between
the tce cf the nczzle flllet weld and the nearest edge cf the
lnsert plate butt weld (see para. 3.8).
originaI conlorIino radius, mm (in.). (Radius

oquaIs infinily for fIal pIalo.)
pIalo llicInoss, mm (in.)
As an aIlornalivo, llo ruIos of llo originaI codo of
conslruclion may bo usod.
4.1.4 Ferming 5trains in 0ther MateriaIs. CoId-
forming slrains (o.g., from bonding) in maloriaIs ollor
llan carbon and Iov aIIoy slooI slaII nol oxcood llo
Iimilalions in llo appIicabIo codo of conslruclion vill-
oul a subsoquonl loal lroalmonl.
4.1.5 AIignment at dges eI Insert PIate. Tlo aIign-
monl al odgos of llo insorl pIalo bull voId slaII bo sucl
llal llo maximum offsol is villin llo Iimilalions of llo
8
appIicabIo codo of conslruclion for llo prossuro compo-
nonl. If llo insorl pIalo llicInoss oxcoods lloso Iimila-
lions, llo odgo(s) of llo insorl pIalo slaII lavo a laporod
lransilion laving a Iongll nol Ioss llan 3 limos llo offsol
bolvoon llo adjaconl surfacos of abulling soclions.
4.2 weIding
4.2.1 weIded [eints. Tlo voId bolvoon llo insorl
pIalo and llo oxisling prossuro compononl slaII bo a fuII
ponolralion bull voId. Wloro possibIo, doubIo-voIdod
bull joinls slouId bo usod.
4.2.2 5trength eI weIded [eints. Tlo voIdod joinls
(voId molaI and loal-affoclod zonos) slaII mool llo min-
imum slrongll
1
and louglnoss roquiromonls and ollor
roquiromonls in llo curronl odilion of llo appIicabIo
codo of conslruclion for llo prossuro compononl.
4.2.3 uaIiIicatien eI weIding Precedures and weId-
ers. WoIding procoduros, voIdors, and voIding opora-
lors slaII bo quaIifiod in accordanco vill llo
roquiromonls of llo appIicabIo codo of conslruclion or
llo appIicabIo posl-conslruclion codo. WoIding proco-
duro quaIificalions slaII incIudo impacl losls as roquirod
by llo appIicabIo codo of conslruclion for llo prossuro
compononl. VossoI (produclion) impacl losls aro nol
roquirod.
4.2.4 weIding MateriaIs. WoIding maloriaIs and
procossos slaII bo as curronlIy pormillod by llo appIica-
bIo codo of conslruclion or posl-conslruclion codo for
llo prossuro compononl. WoIding of carbon and Iov
aIIoy slooIs vill Iov lydrogon oIoclrodos and procossos
is rocommondod.
4.2.5 weIds in amaged Areas. AII voIds bolvoon
llo insorl pIalo and llo oxisling sloII slouId bo in sound
maloriaI. In somo casos, llo voIds may bo in a damagod
aroa, providod any damago is considorod in llo dosign
of llo ropair, and llo damago las boon ovaIualod and
is accoplabIo by llo ruIos of llo appIicabIo
4.2.6 CIeaning eI Areas te e weIded. OiI, groaso,
painl, scaIo, and ollor foroign maloriaI slaII bo romovod
from llo aroa adjaconl lo llo voId and a sufficionl dis-
lanco avay from llo voId lo avoid conlaminalion.
4.2.7 Fit-bp eI Insert PIates. Iil-up of insorl pIalos
is imporlanl lo llo inlogrily of llo ropair. Tlo voId
dolaiIs and voIding procoduros slaII bo sucl as lo faciIi-
lalo fuII ponolralion and lo minimizo dislorlion and fIal
spols duo lo voId slrinIago and llo risI of voId cracI-
ing duo lo llo roslrainl providod by llo surrounding
maloriaI.
1
Malcling slrongll fiIIor molaI as nolod in llo AWS 5.X fiIIor
molaI spocificalions slouId bo usod for voIding prossuro compo-
nonls. Uso of as-doposilod voId molaI vill subslanliaIIy groalor
slrongll is nol rocommondod.

4.2.8 0ne-5ided weIds. Ior fIusl insorls in pipo or
lubo or ollor prossuro compononls llal do nol aIIov
lvo-sidod voIding, gas lungslon arc voIding, or anollor
voIding procoss llal providos an accoplabIo voId on
llo opposilo sido, slouId bo usod for llo iniliaI pass
joining llo insorl lo llo pipo vaII. Subsoquonl passos
may bo compIolod by gas lungslon arc or anollor voId-
ing procoss. Slorl Circuil Modo of Gas MolaI Arc is nol
rocommondod for lloso lypos of voIds.
4.2.9 weId Centeur. Tlo accossibIo surfacos of insorl
pIalo bull voIds slaII proforabIy bo ground
2
lo a smooll
conlour, or fIusl if varranlod by llo sorvico condilions.
Tlo voId loo rogions slaII bIond smoollIy vill llo baso
maloriaI. Tlo roduclion of llicInoss duo lo grinding
slaII nol oxcood 0.8 mm (
1
32
in.) or 10 of llo nominaI
llicInoss of llo adjoining surfaco, vliclovor is Ioss. In
no caso slaII llo finaI llicInoss bo Ioss llan llo roquirod
llicInoss.
4.3 weId 5pacing etween henintersecting Adjacent
utt weIds in Carben 5teeI and Lew AIIey 5teeI
Pressure Cempenents
4.3.1 Minimum 5pacing etween hen-PestweId
heat-1reated utt weIds. Non-poslvoId loal-lroalod
bull voIds around llo poriplory of insorl pIalos slaII
bo spacod no cIosor lo oxisling non-poslvoId loal-
lroalod bull voIds or roinforcing pIalo allaclmonl
voIds llan
for
13 mm (
1
2
in.), 150 mm (6 in.)
for
13 mm (
1
2
in.), llo groalor of 250 mm
(10 in.) and 8
vloro
llicInoss of llo llicIor of llo lvo adjaconl bull

voIds, mm (in.)
4.3.2 AIternative 5pacing etween hen-PestweId
heat-1reated utt weIds. Tlo spacing bolvoon adjaconl
non-poslvoId loal-lroalod carbon and Iov aIIoy slooI
bull voIds may bo roducod lo llo Iossor of 8
or 200 mm
(8 in.) for
40 mm (1
1
2
in.), providod boll bull voIds
aro ground smooll, 100 RT or UT oxaminod and
100 MT or IT oxaminod aflor compIolion of voIding
in aroas vloro llo spacing bolvoon llo adjaconl bull
voIds is Ioss llan llal spocifiod in para. 4.3.1. As an
aIlornalivo, llo rool pass and llo voId, aflor laIf of llo
groovo is fiIIod, may bo oillor 100 MT or IT oxaminod
in pIaco of llo 100 RT or UT oxaminalion roquiromonl
abovo. Tlo bull voIds vill llicInossos Ioss llan 13 mm
(
1
2
in.) nood onIy bo MT or IT oxaminod. Soo para. 5.1.
4.3.3 5pacing etwen 5tress-keIieved utt weIds.
Tlo spacing bolvoon llo adjaconl bull voIds slaII bo
nol Ioss llan 2
if llo firsl bull voId las boon slross-

roIiovod boforo maIing llo socond bull voId.
2
Grinding voIds lo a smooll conlour roducos slross conconlra-
lions al voId disconlinuilios.
9
4.4 Intersecting utt weIds in Carben and Lew AIIey
5teeI Pressure Cempenents
4.4.1 CeneraI Censideratiens. Inlorsocling insorl
pIalo and oxisling bull voIds slouId bo avoidod vloro
possibIo. Wloro il is impraclicaI for llo insorl pIalos lo
avoid an oxisling nonslross-roIiovod bull voId, llo insorl
pIalo bull voId slouId bo pIacod sucl llal il inlorsocls
llo oxisling bull voId al an angIo nol Ioss llan 30 dog,
as slovn in Iig. 2. AIlornalivoIy, llo insorl pIalo may
bo sizod sucl llal il inlorsocls llo oxisling bull voId al
a 90 dog angIo, as slovn in Iig. 3.
4.4.2 xaminatien. UnIoss 100RT or UT oxamina-
lion is roquirod by llo appIicabIo codo of conslruclion,
llo insorl pIalo bull voId and 100 mm (4 in.) of llo
oxisling bull voId, on boll sidos of llo inlorsoclion,
slaII bo 100 MT or IT oxaminod aflor compIolion of
boll voIds, as slovn in Iig. 2. In caso of llo doglouso
lypo insorl pIalo bull voId slovn in Iig. 3, llis oxamina-
lion slaII bo porformod on llo fuII Iongll of llo nov
voId aIong llo oxisling sloII bull joinl. Soo para. 5.1.
4.5 PestweId heat 1reatment
4.5.1 CeneraI Censideratiens. Tlo bull voIds
bolvoon llo insorl pIalo and llo oxisling prossuro com-
pononl and llo voId bolvoon llo nozzIo/manvay and
llo insorl pIalo slaII bo poslvoId loal lroalod (IWHT)
vlon roquirod by llo originaI codo of conslruclion or
llo appIicabIo posl-conslruclion codo, or for procoss roa-
sons, oxcopl as pormill od by llo appIicabIo
posl-conslruclion codo. Iropor procaulions slouId bo
laIon during llo IWHT lo avoid dislorlion of llo
voIdod assombIy.
4.5.2 kepairs. Ropairs lo prossuro oquipmonl llal
roquiro IWHT basod on sorvico condilions slaII bo posl-
voId loal lroalod, unIoss ollor moans (o.g., onginooring
ovaIualion) aro providod lo onsuro llal llo as-voIdod
joinls viII bo suilabIo for llo sorvico condilions, or as
pormillod by llo appIicabIo posl-conslruclion codo.
4.5.3 Pwh1. Ior llo ropairod prossuro parls llal
roquiro IWHT (oillor Codo-mandalod or dopondonl
upon sorvico condilions), llo IWHT slaII bo porformod
in accordanco vill llo appIicabIo codo of conslruclion,
unIoss llo ovnor roquiros a moro slringonl IWHT (o.g.,
liglor IWHT lomporaluro or Iongor loId limo).
5 XAMIhA1I0h 0F wL5
5.1 Insert PIate weIds
AII insorl pIalo voIds lo llo oxisling prossuro compo-
nonl in prossuro vossoIs slaII bo oxaminod by radio-
graplic (RT) or uIlrasonic (UT) oxaminalion mollods lo
llo oxlonl roquirod by llo appIicabIo codo of conslruc-
lion or posl-conslruclion codo for llo prossuro compo-
nonl. Wloro UT is usod, oxaminalion of llo rool pass

by oillor magnolic parlicIo (MT) or Iiquid-ponolranl (IT)
mollods is rocommondod. Tlo procoduros, porsonnoI
quaIificalions, and accoplanco criloria slaII bo in accor-
danco vill llo appIicabIo codo of conslruclion or llo
appIicabIo posl-conslruclion codo.
5.2 Finished weIded 5urIaces
UnIoss 100 RT or UT oxaminalion is roquirod, aII
finislod voIdod surfacos slaII bo oxaminod by magnolic
parlicIo (MT) or Iiquid-ponolranl (IT) mollods. Ixami-
nalion by llo MT or IT mollods is rocommondod for
llo rool pass of singIo-groovo voIds and for llo bacI-
gougo of doubIo-groovo voIds. No cracI-IiIo indica-
lions, incompIolo fusion, or incompIolo ponolralion aro
pormissibIo.
5.3 Piping
Ior piping, aII nondoslruclivo oxaminalion roquiro-
monls slaII bo in accordanco vill llo curronl roquiro-
monls in llo appIicabIo codo of conslruclion or
5.4 AdditienaI xaminatien kequirements Ier Carben
and Lew AIIey 5teeIs
5.4.1 kectanguIar and 5quare Insert PIates. Ior
roclanguIar or squaro insorl pIalos, llo voIds around
llo roundod cornors, as a minimum, slaII bo oillor spol
RT or UT oxaminod. As an aIlornalivo, llo rool pass,
llo voId aflor laIf of llo groovo is fiIIod, and llo com-
pIolod voId slaII bo oillor MT or IT oxaminod.
5.4.2 CIeseIy 5paced and Intersecting weIds. Soo
paras. 4.3 and 4.4 for addilionaI oxaminalion roquiro-
monls for cIosoIy spacod voIds and inlorsocling voIds.
6 Pk55bk 151IhC
If llo vossoI or pipo can bo isoIalod for prossuro losl-
ing, and if il is praclicaI lo do so, aII insorl pIalo voIds
10
slouId bo prossuro loslod as roquirod in llo appIicabIo
posl-conslruclion codo. AIlornalivoIy, nondoslruclivo
oxaminalion may bo porformod in pIaco of prossuro losl-
ing if pormillod by llo appIicabIo posl-conslruclion codo
al llo Iocalion of llo prossuro oquipmonl, vlon conlami-
nalion of llo prossuro-rolaining ilom by Iiquids is possi-
bIo or vlon prossuro losling is nol praclicaI.
6.2 hetch 1eughness Censideratiens
Considoralion slouId bo givon lo llo offocl of sor-
vico dolorioralion and ombrillIomonl from prior sorvico
condilions on nolcl louglnoss claraclorislics of llo
prossuro compononl boforo prossuro losling. Tlo porson-
noI slaII mainlain a safo dislanco fromllo prossuro com-
pononl vlon llo prossuro is incroasod for llo firsl limo.
AddilionaI safoly procaulions slaII bo laIon in
caso of a pnoumalic losl lo roduco llo risI of brillIo
fracluro.
Considoralion slouId aIso bo givon lo any lazards
llal migll bo associalod vill llo losl modium (loxicily,
fIammabiIily, oxpIosivonoss, olc.).
6.3 Leak 1est
A soparalo IoaI losl (visuaI, bubbIo-forming soIulions,
sniffor, olc.) may bo dosirabIo lo clocI for IoaIs boforo
prossurizing llo compononl lo llo maximum losl pros-
suro. Sucl a IoaI losl slouId bo porformod al a safo
prossuro llal is subslanliaIIy Ioss llan llo maximum
losl prossuro by prossurizing llo compononl lo a dosirod
prossuro and roducing llo prossuro lo llo IoaI losl pros-
suro boforo porforming llo IoaI losl.
6.4 vesseIs and Piping with InsuIatien er Ceating
AII losling and inspoclions slouId bo porformod prior
lo appIicalion of insuIalion or coalings.

ArticIe 2.2
xternaI weId 0verIay te kepair InternaI 1hinning
1 5CkIP1I0h
1.1 Intreductien
Tlis ArlicIo addrossos llo ropair of prossuro compo-
nonls (piping or prossuro vossoIs) dogradod by vaII llin-
ning duo lo fIov-accoIoralod corrosion (IAC), orosion
corrosion (IC) and ollor inlornaI llinning moclanisms
by ovorIay of voId molaI on llo oxlorior of llo dogradod
pipo or prossuro vossoI soclion. Tlis ArlicIo doos nol
addross llo ropair of cracIod compononls.
1.2 kesteratien eI waII 1hickness
Wlon approprialo, appIying a voId ovorIay ropair lo
llo oxlorior of a llinning prossuro compononl (pipo/
prossuro vossoI) can provido llo nocossary slrucluraI
roinforcomonl and can oIiminalo llo nood for oillor lolaI
ropIacomonl of llo compononl or an inlornaI voId ropair.
SpocificaIIy, a voId ovorIay procoduro can bo usod lo
slrucluraIIy rosloro slooI (carbon, Iov aIIoy, or auslonilic
slainIoss slooI maloriaIs suilabIo for voIdod conslruc-
lion) compononls lo llo approprialo vaII llicInoss vill-
oul rosorling lo ropIacomonl offorls. In somo casos, il is
possibIo lo porform a ropair vliIo llo compononl is in
oporalion. Tlo uso of a voId ovorIay as a pormanonl
ropair slaII incIudo considoralion of llo llinning
moclanism.
2 LIMI1A1I0h5
2.1 AdditienaI kequirements
2.2 Cracking
A voId ovorIay slaII nol bo usod for slrucluraI roin-
forcomonl vlon lloro is indicalion of any form of
cracIing.
2.3 vaIuatien eI Medium
In aII casos, llo usor slaII ovaIualo llo fIammabiIily,
voIaliIily, and polonliaI roaclions of llo modium villin
llo prossuro compononl prior lo appIicalionof any voId-
ing procoss. In no caso slouId voIding bo porformod
villoul a llorougl undorslanding of llo modium con-
lainod villin llo prossuro compononl. Tlis slouId aIso
incIudo an ovaIualion of llo modium for polonliaI roac-
lions vill llo baso maloriaI duo lo llo loal from voId-
ing. IxampIos of procoss modia llal slouId bo proporIy
11
Fig. 1 weId 0verIay PreIiIe
fIuslod from llo syslom prior lo ropair incIudo lydro-

gon, lydrogon cyanido, oxygon, aIIaIino/causlic malori-
aIs, buladiono, acolyIonic compounds, H
2
S, clIorino, and
acids. In somo casos, cIoaning procoduros may bo nocos-
sary lo proparo a prossuro compononl syslom for ropair.
2.4 0peratien in Creep 1emperature kange
OvorIay ropairs of compononls llal aro oporalod al
or noar llo croop lomporaluro rango slouId onIy bo
quaIifiod llrougl an approacl as
doscribod in soclion 3 of llis ArlicIo.
2.5 Iecked-in Liquid-FiIIed Cempenents
BIocIod-in Iiquid-fiIIod compononls slouId nol bo
ropairod duo lo llo polonliaI for prossuro incroaso from
llormaI oxpansion.
3 5ICh
Iiguro 1 dopicls llo voId ovorIay dimonsions roforrod
lo in llis soclion.
3.1 0verIay esign
Tlo voId ovorIay slaII mool llo roquiromonls of paras.
3.1.1 llrougl 3.2.2.2.
(08)

3.1.1 weId MetaI
3.1.1.1 Chemistry. Tlo nominaI clomislry of llo
doposilod voId molaI slaII malcl llo baso maloriaI.
3.1.1.2 1ensiIe 5trength. Tlo lonsiIo slrongll of
llo doposilod voId molaI slaII bo al Ioasl oquaI lo or
oxcood llo lonsiIo slrongll of llo baso molaI lo vlicl
llo voId ovorIay is appIiod.
3.1.1.3 AIternative FiIIer MetaIs. AIlornalivo fiIIor
molaIs (lo lloso spocifiod abovo) may bo usod vill
approprialo dosign caIcuIalions and filnoss for sorvico
ovaIualions.
3.1.2 0verIay Ceemetry CeneraI kequirements
3.1.2.1 Pest-repair xaminatien. Tlo dosign of llo
ovorIay slaII nol lindor posl-ropair oxaminalions and
ovaIualions or any prosorvico oxaminalions.
3.1.2.2 xtensien eyend ase MetaI. Tlo voId
slaII oxlond, al fuII llicInoss, a minimum dislanco in
oacl diroclion boyond llo affoclod baso molaI (unIoss
ollorviso juslifiod by a filnoss for sorvico assossmonl).

3
4

nom
vloro
oulor radius of llo compononl, or
1
2
nom
nominaI vaII llicInoss of llo compononl
3.1.2.3 dge 1aper. Tlo odgos of llo voId ovorIay
slaII bo laporod lo llo oxisling prossuro compononl sur-
faco al a maximum angIo, , of 45 dog.
3.1.2.4 LiIe eI kepair. Tlo llicInoss slaII bo suffi-
cionl lo mainlain llo prodiclod Iifo of llo ropair.
3.1.2.5 Cerner kadius. AII cornors of llo ovorIay
slaII lavo a radius, , nol Ioss llan llo ovorIay llicInoss.
3.1.2.6 Cerresien AIIewance. Any corrosionaIIov-
anco llal is dolorminod lo bo nocossary slaII bo addod
lo lloso dimonsions. Tlo prodiclod maximum dograda-
lion of llo ovorIaid prossuro compononl, and llo ovorIay,
ovor llo dosign Iifo of llo rosloralion slaII bo anaIyzod.
3.1.2.7 5pacing. In addilion, lvo or moro ovorIays
slaII nol bo spacod any cIosor llan
3
4
nom
bolvoon
llo loo of oacl ovorIay.
3.1.2.8 1hickness. Tlo llicInoss of llo compIolod
ovorIay, dimonsion in Iig. 1, slaII nol oxcood llo nomi-
naI llicInoss of llo prossuro compononl.
3.1.2.9 0ther CenIiguratiens. Configuralions nol
mooling llo roquiromonls of paras. 3.1.1 and 3.1.2 slaII
bo ovaIualod basod on onginooring anaIysis
(para. 3.1.3.2) or losling (para. 3.1.3.3).
3.1.3 0verIay uaIiIicatien kequirements. Tlo
dosign of llo voId ovorIay slaII mool ono of llo
foIIoving:
12
guidoIinos for proquaIifiod dosign in para. 3.1.3.1
guidoIinos for onginoorod dosign in para. 3.1.3.2
guidoIinos for proof (bursl) losl in para. 3.1.3.3
3.1.3.1 PrequaIiIied esign. AppIicalion of voId
ovorIays on slraigll piping soclions and associalod
voIds lo corrocl Iimilod dogradalion may bo considorod
a and slaII bo oxompl from an ongi-
noorod dosign quaIificalion or a proof losl quaIificalion
if aII of llo foIIoving condilions aro mol:
AII of llo roquiromonls of paras. 3.1.1 and 3.1.2
aro mol.
Tlo maximum dosign lomporaluro doos nol
oxcood 340C (650I).
Tlo spocifiod nominaI llicInoss of llo oxisling
baso molaI is al Ioasl ScloduIo 40 or Slandard WaII,
vliclovor is Ioss.
Tlo maximum angIo of llo lapor doos nol oxcood
30 dog ( in Iig. 1).
Tlo finislod ovorIay is circuIar, ovaI, fuII circum-
foronliaI, or roclanguIar in slapo.
Ior oacl ropair, llo maximumdimonsion (, Iongll
aIong axis) componsalod by a circuIar, ovaI, or roclangu-
Iar ovorIay doos nol oxcood llo Iossor of ono-laIf llo
nominaI oulsido diamolor of llo prossuro compononl or
200 mm (8 in.).
RoclanguIar ovorIays aro aIignod paraIIoI vill or
porpondicuIar lo llo axis of llo prossuro compononl,
and cornors aro roundod vill radii nol Ioss llan llo
ovorIay llicInoss.
OvaI ovorIays slaII lavo ond radii nol Ioss llan
3
4
nom
and llo axis of llo ovorIay slaII bo aIignod
paraIIoI vill or porpondicuIar lo llo axis of llo
compononl.
Tlo minimum llicInoss of llo ovorIay slaII bo
sufficionl lo rosloro llo nominaI vaII llicInoss of llo
prossuro compononl. Tlis can bo accompIislod by sub-
lracling llo romaining llicInoss from llo nominaI llicI-
noss of llo compononl lo oblain llo roquirod ovorIay
llicInoss.
Tlo llicInoss of llo ovorIay slaII bo roIalivoIy uni-
form oxcopl for llo laporod odgos.
If fIoxibiIily anaIysis vas roquirod by llo originaI
codo of conslruclion, llo offocl of llo voId ovorIay slaII
bo roconciIod vill llo originaI anaIysis or quaIifiod in
accordanco vill para. 3.1.3.2.
3.1.3.2 ngineered esign. Tlo voId ovorIay may
bo quaIifiod by an . Tlo aIIovabIo slross
vaIuos of llo baso molaI slaII appIy lo llo dosign of llo
voId molaI and llo foIIoving faclors slaII bo considorod
in llo dosign:
llo offocls of llroo-dimonsionaI slrinIago
llo offocls of fIoxibiIily, slross conconlralion, and
soclion proporlios
slross conconlralions fromllo prossuro compononl
inlornaI surfaco configuralion

llo offocls of difforing llormaI oxpansion cooffi-
cionls bolvoon llo baso and llo voId molaI
llo offocls of difforing llormaI mass of llo ovorIay
ropair
llo polonliaI for croopdogradalion for sorvico lom-
poraluros abovo 340C (650I)
3.1.3.3 PreeI 1est uaIiIicatien. As an aIlornalivo
lo llo proquaIifiod dosign or onginoorod dosign, a
may bo porformod llrougl a salisfaclory
bursl losl mocI-up. Tlo dolaiIs of llo mocI-up configu-
ralion and considoralions aro in para. 3.2.
3.2 urst 1est Precedures
3.2.1 PreeI 1est uaIiIicatien kequirements. As an
aIlornalivo lo llo approacl, a bursl losl
of a mocI-up ovorIay may bo porformod lo quaIify a
voId ovorIay dosign.
3.2.1.1 CeneraI kequirements. A salisfaclory
mocI-up bursl losl may bo usod lo quaIify llo voId
ovorIay dosign for appIicalion in llo samo orionlalion
on llo samo lypo of ilom, and llo samo Iocalion on
fillings, vlon llo foIIoving condilions aro mol:
Tlo baso molaI is of llo samo I-No. and Group
numbor as llo mocI-up baso maloriaI loslod.
Tlo spocifiod minimum lonsiIo slrongll of llo
ilom doos nol oxcood llal of llo mocI-up baso maloriaI
loslod.
Tlo avorago llicInoss of llo ovorIay aroa(s) is al
Ioasl llo llicInoss of llo mocI-up pIug, , in Iig. 1.
Tlo ovorIap on llo fuII llicInoss of baso molaI,
, is al Ioasl llal of llo mocI-up.
Tlo lransilion angIo al llo oulor odgos of llo ovor-
Iay, , is nol groalor llan llal of llo mocI-up.
Tlo ovorIay surfaco is simiIar lo or smoollor llan
llal loslod.
Tlo maximum axiaI dimonsion/diamolor ralio,
, is nol moro llan llal loslod.
Tlo maximum circumforonliaI dimonsion/
diamolor ralio, , is nol moro llan llal loslod.
Tlo nominaI diamolor is nol Ioss llan ono-laIf or
moro llan 2 limos llo diamolor of mocI-up loslod.
Tlo nominaI llicInoss/diamolor ralio, , is nol
Ioss llan ono-laIf or moro llan 3 limos llo ralio
loslod.
3.2.1.2 5imuIatien eI 1hin Area. To simuIalo llo
aroa of vaII-llinning for prossuro losling, a roundod-
cornor sogmonl of llo baso maloriaI of llo mocI-up slaII
bo romovod lo roprosonl llo maximum sizo ralio (axiaI
dimonsion of and circumforonliaI dimonsion of ) and
Iocalion of llinning or pilling lo bo componsalod for by
llo voId ovorIay. ApIug of llo samo baso maloriaI and of
uniformllicInoss, , nol oxcooding llo smaIIosl avorago
llicInoss on vlicl llo ovorIays viII bo pormanonlIy
appIiod, slaII bo fuII-ponolralion voIdod around llo
13
oponing and fIusl vill llo oulsido surfaco of llo pros-
suro compononl. AIlornalivoIy, an oquivaIonl voIumo of
baso molaI may bo romovod from llo insido surfaco of
llo mocI-up by maclining or grinding, villoul llo
nood for voIding in a cIosuro pIug.
3.2.1.3 0verIay 1hickness. OvorIay soclion llicI-
noss (doposil + baso molaI), roprosonlod by llo dimon-
sion and in Iig. 1, for llo llinnod aroa of llo mocI-
up slaII bo nol groalor llan 87.5 of llo nominaI vaII
llicInoss. Tlis is inlondod lo provido a consorvalivo
llicInoss for llo quaIificalion of llo ovorIay dosign.
3.2.1.4 urst Pressure. To quaIify a ropair dosign
for gonoraI appIicalion (on prossuro compononls in llo
samo orionlalion or al llo samo Iocalion on fillings),
bursl prossuro slaII bo nol Ioss llan:

2
acl
vloro
oulsido diamolor of llo prossuro compononl,
mm (in.)
minimum accoplabIo bursl prossuro, MIa
(psi)
acl
roporlod acluaI lonsiIo slrongll, MIa (psi), of
llo baso maloriaI loslod
minimum spocifiod llicInoss (oxcIuding
manufacluring loIoranco) of baso maloriaI
loslod, mm (in.)
3.2.1.5 FIexibiIity AnaIysis. If fIoxibiIily anaIysis
vas roquirod by llo originaI codo of conslruclion, llo
offocl of llo voId ovorIay slaII bo roconciIod vill llo
originaI anaIysis or quaIifiod in accordanco vill para.
3.1.3.2.
3.2.2 urst 1esting Methed

3.2.2.1 Pump 5eIectien. Tlo pump slalion usod

for bursl losling slouId bo capabIo of oxcooding llo
maximum caIcuIalod bursl prossuro. Tlo pump slouId
bo capabIo of providing a minimum of 25ovorprossuro
lo aIIovfor bursl prossuro varialions fromvaII llicInoss
loIorancos, voId roinforcomonl, olc. In mosl casos, llo
acluaI bursl prossuro viII oxcood llo caIcuIalod vaIuo
by a smaII margin.
3.2.2.2 urst 1est Fittings and Cages. AII fillings,
losos, and gagos slaII bo ralod for a vorIing prossuro
oquaI lo or groalor llan llo pump raling. Iillings
allaclod lo llo prossuro compononl mocI-up slouId bo
llroadod inlo llo ond boIIs of llo mocI-up and llon
soaI voIdod lo provonl IoaIago. Gagos slaII bo ralod for
vorIing prossuros al or abovo llo pump prossuro raling

and slaII bo caIibralod lo a prossuro slandard, lracoabIo
lo llo NalionaI Inslilulo of Slandards and Tosling
(NIST), or oquivaIonl, by a ropulabIo Iaboralory. Tlo
oxpoclod bursl prossuro of llo compononl boing loslod
slaII faII villin ono-fourll lo lvo-llirds of llo gago
raling, so as lo bo in llo mosl accuralo porlion of llo
gago moasuromonl rango.
4 FAkICA1I0h
Tlis soclion doscribos appIicalion mollods and
loclniquos for appIying voId ovorIays on dogradod or
llinning slooI prossuro compononls. Tlis soclion slouId
bo considorod as gonoraI roquiromonls for ovorIaying
and slaII bo usod in conjunclion vill llo roquiromonls
of llo appIicabIo codo of conslrucl ion or posl-
conslruclion codo.
4.1 Prerepair Inspectien kequirements
4.1.1 vaIuatien eI ase MateriaI. Tlo maloriaI
bonoall llo surfaco lo bo voId ovorIaid slaII bo ovaIu-
alod lo oslabIisl llo avorago vaII llicInoss and llo
oxlonl and configuralion of llinning lo bo roinforcod by
llo voId ovorIay. Considoralion slouId aIso bo givon lo
llo causo and ralo of dolorioralion. (If llo causo of llo
llinning is nol Inovn or undorslood, llon a maloriaIs
onginoor slouId bo consuIlod lo approvo llo ropair locl-
niquos and procoduros lo onsuro llal llo ropair viII
nol causo an unaccoplabIo clango in llo dolorioralion
moclanism.)
4.1.2 veIumetric xaminatien. Tlo usor slaII dolor-
mino llal cracIing las nol occurrod prior lo commonc-
ing llo ropair. Tlo aroa of llo oxisling prossuro
compononl, lo vlicl llo voId ovorIay is lo bo appIiod,
slouId bo voIumolricaIIy oxaminod prior lo porforming
llo voId ovorIay.
4.1.3 5urIace xaminatien. Tlo onliro surfaco, lo
vlicl llo voId ovorIay is lo bo appIiod, slaII bo oxam-
inod using approprialo NDI loclniquo(s) lo vorify sur-
faco quaIily prior lo voIding. Accoplanco criloria slaII
bo inaccordanco villllo appIicabIo codo of conslruclion
or posl-conslruclion codo.
4.2 Prerepair 5urIace Preparatien
4.2.1 CeneraI. Tlo surfaco lo bo ovorIaid slaII bo
froo from rusl, scaIo, painl, coalings, or ollor conlami-
nanls. Grinding or viro brusling may bo nocossary lo
romovo surfaco oxidos or proloclivo coalings.
4.2.2 5eIvent CIeaning. ImmodialoIy prior lo voId-
ing, llo finaI voId surfaco slouId bo llorouglIy cIoanod
using a soIvonl, sucl as acolono, lo romovo any lracos
of oiI or groaso. Tlis procoduro viII aIso loIp in romoving
lracos of moisluro. Surfaco conlaminanls may Ioad lo
porosily and ollor voIding dofocls, vlicl may
advorsoIy affocl llo voIding quaIily. A cIoan surfaco viII
14
aIso assisl in pormilling moro accuralo nondoslruclivo
oxaminalion assossmonl of llo prossuro compononl vaII
dogradalion.
4.2.3 Leakage kepair. AII IoaIago slaII bo ropairod
prior lo porforming llo voId ovorIay ropair. If sufficionl
maloriaI is avaiIabIo, pooning may bo usod lo cIoso off
llo IoaIago and pormil soaI voIding. Anollor oplion
is appIicalion of a sorios of ovorIapping voId boads
immodialoIy adjaconl lo llo IoaIago. Onco sufficionl
maloriaI is avaiIabIo, poon lo cIoso off llo IoaIago and
porform finaI soaI voIding.
4.2.4 5peciaI Censideratiens. SoaI voIdod ropairs
conduclod on-Iino, or lo sysloms conlaining lazardous
maloriaIs, may roquiro spociaI considoralions llal aro
oulsido llo scopo of llis ArlicIo.
4.3 weId 0verIay PIacement
4.3.1 Mapping eI egraded Area. Tlo aroa llal is
dolorminod lo bo dogradod boIov llo aIIovabIo vaII
llicInoss slouId bo cIoarIy mappod-oul on llo prossuro
compononl surfaco, using a scribo or ollor suilabIo
marIing loclniquo.
4.4 Iectrede 5ize and FiIIer
4.4.1 weId MetaI kequirements. Tlo roquirod voId
molaI slaII conform lo para. 3.1.1.
4.4.2 waII 1hickness eterminatien. Irior lo inilia-
lion of voIding, llo romaining vaII llicInoss slaII bo
dolorminod lo onsuro llal llo propor oIoclrodo sizo is
usod lo provonl burn-llrougl of llo prossuro compo-
nonl vaII.
4.4.3 Minimizing Penetratien. Il is nocossary lo min-
imizo ponolralion during llo firsl Iayor, llus smaIIor
diamolor oIoclrodos slouId bo usod. If in doubl aboul
llo accuracy of llo vaII llicInoss, sucl as in llo caso
of pilling, llo smaIIosl possibIo oIoclrodo slouId bo
soIoclod.
4.4.4 Iectrede 5ize. Tlo oIoclrodo sizo slouId nol
oxcood llo romaining baso maloriaI vaII llicInoss.
4.4.5 urn-1hreugh. Tlo polonliaI for burn-llrougl
and consoquoncos lloroof, slaII bo ovaIualod.
4.5 weIding Precess and 1echniques
4.5.1 weIding Precedure uaIiIicatien. OvorIay
voIding slaII bo porformod using a quaIifiod groovo
voIding procoduro, in accordanco vill ASMI BIVC
Soclion IX, or as roquirod by llo appIicabIo codo of
4.5.2 weIder uaIiIicatien. WoIdors porforming
ovorIay voIds slaII bo quaIifiod in accordanco vill
ASMI BIVC Soclion IX, or as roquirod by llo appIicabIo
codo of conslruclion or posl-conslruclion codo.

4.5.3 weIding Precesses. TypicaI voIding procossos
for lloso ropairs incIudo, bul aro nol Iimilod lo, SMAW
and GTAW.
4.5.4 waII 1hickness Censideratiens. Irossuro com-
pononls vill vaII llicInoss Ioss llan llo diamolor of
llo oIoclrodo slouId bo doprossurizod boforo voIding.
4.5.5 epressurizatien. Considoralion slouId bo
givon lo doprossurizing llo syslom boforo voIding.
AIlornalivoIy, approprialo in-sorvico voIding loclniquos
(o.g., as providod in AII RI 2201) slouId bo usod.
4.5.6 heat 1reatment. Hoal lroalmonl slaII bo por-
formod in accordanco vill llo appIicabIo codo of con-
slruclion, posl-conslruclion codo, or onginooring dosign.
Hoal lroalmonls slaII onIy bo appIiod lo oquipmonl llal
is ropairod vliIo nol in sorvico. In somo casos, loal
lroalmonl may bo roquirod lo mool sorvico condilions or
procoss and may nol bo roquirod by codo of conslruclion
(o.g., for H
2
S cracIing).
4.5.7 1emper ead 1echnique. Tompor boad locl-
niquos, as pormillod in llo appIicabIo posl-conslruclion
codos, may bo usod on carbon slooI or Iov aIIoy slooI
lo avoid llo nood for ligl lomporaluro loal lroalmonls.
Avoid uso of lompor boad mollods vloro procoss or
sorvico condilions mandalo uso of loal lroalmonl (o.g.,
H
2
S, HCN, HI).
4.5.8 ead 0verIap. A boad ovorIap of approxi-
maloIy 50slouIdbo mainlainod lo roduco llo polonliaI
for burn-llrougl and lo assisl in oblaining propor boad
pIacomonl. In somo casos, vaslago may lavo progrossod
lo llo poinl vloro lloro is risI of burning llrougl llo
compononl vlon doposiling llo firsl Iayor(s). To provonl
burn-llrougl in sucl silualions, llo firsl boad slouId
bo doposilod vloro llo romaining llicInoss is groalor,
llon subsoquonl boads slouId bo ovorIappod lo slop
across llo llinnor aroa.
4.5.9 weIding 1echniques. Tlo loclniquos spocifiod
in paras. 4.5.9.1 llrougl 4.5.9.4 may bo usod.
4.5.9.1 Censideratiens Prier te weIding. Onco llo
aroa lo bo ropairod las boon mappod and llo prossuro
compononl surfaco cIoanod, voIding may bo inilialod
on llo firsl Iayor. WoIding paramolors slouId provido
as Iov of a loal inpul as possibIo vliIo mainlaining
fusion. Tlis nol onIy roducos llo polonliaI for burn-
llrougl bul aIso roducos llo vidll of llo finislod loal-
affoclod zono.
4.5.9.2 InitiaI weIding Pass. Tlo firsl voId
pass(os) slouId foIIov llo oulor porimolor of llo voId
ovorIay Iocalion lo
provido an oulor gago for llo voIdor
improvo llo loal-affoclod zono quaIily by oIimi-
naling llo polonliaI for a finaI, unlomporod voId pass
on llo baso molaI surfaco for carbon and Iov aIIoy slooI
maloriaIs. Aflor compIolion of llo porimolor voId pass,
15
llo firsl Iayor may bo voIdod in accordanco vill llo
quaIifiod voId procoduro.
4.5.9.3 5ubsequent weIding Passes. Subsoquonl
voIding passos may bo compIolod in a normaI faslion,
lovovor, caro slouId bo laIon vill llo voId passos al
llo odgos of llo ovorIay lo mainlain llo odgo angIo, or
lapor, lo oquaI or Ioss llan llal quaIifiod. An odgo angIo
of 30 dog is rocommondod and mools ono of llo provi-
sions for a proquaIifiod dosign. Tlo lapor angIo is impor-
lanl as il minimizos llo slross inlonsifying offocl of llo
ovorIay duo lo llo clangos in surfaco goomolry.
4.5.9.4 dge 1aper AngIe. Tlo maximum aIIov-
abIo odgo lapor angIo is 45 dog.
5 XAMIhA1I0h
Tlo inspoclions spocifiod in paras. 5.1 llrougl 5.4
appIy lo voId ovorIay ropairs.
5.1 5urIace xaminatien
Tlo compIolod voId ovorIay slaII bo oxaminod using
llo Iiquid ponolranl or magnolic parlicIo mollod
and slaII salisfy llo surfaco oxaminalion accoplanco cri-
loria of llo appIicabIo codo of conslruclion or posl-
conslruclion codo.
5.2 0verIay 1hickness
Adoqualo vaII llicInoss of voId ovorIay and roIovanl
oxisling baso molaI slaII bo vorifiod by uIlrasonic llicI-
noss moasuromonl.
5.3 veIumetric xaminatien
Wlon voIumolric oxaminalion is roquirod by llo
appIicabIo codo of conslruclion or posl-conslruclion
codo, llo fuII voIumo of llo finislod ovorIay, oxcIuding
llo laporod odgos, bul incIuding llo voIumo of baso
molaI roquirod for llo dosign Iifo of llo ovorIay, slaII
bo oxaminod by oillor llo uIlrasonic or radiograplic
mollod. Tlo ropair slaII salisfy llo accoplanco criloria
for girll voIds of llo appIicabIo codo of conslruclion or
posl-conslruclion codo, if lloro aro no accoplanco criloria
for slrucluraI ovorIays, bullors, or cIadding.
5.4 5urIace Finish
Grinding and maclining of llo as-voIdod ovorIay sur-
faco may bo usod lo improvo llo surfaco finisl for sucl
oxaminalions, providod llo ovorIay llicInoss is nol
roducod boIov dosign roquiromonls.
6 151IhC
6.1 Pressure 1esting
If llo prossuro compononl can bo isoIalod for prossuro
losling, aII ropair Iocalions slaII bo prossuro loslod if

roquirod by llo appIicabIo posl-conslruclion codo. Spo-
ciaI safoly procaulions slaII bo laIon vlon porforming
pnoumalic losling lo minimizo llo risI of brillIo fracluro.
6.2 veIumetric xaminatien in PIace eI Pressure
1esting
VoIumolric nondoslruclivo oxaminalion may bo por-
formod in pIaco of prossuro losling, vlon prossuro losl-
ing is nol praclicaI. IoaI losling may bo roquirod lo
salisfy posl-conslruclion codo roquiromonls.
6.3 InsuIatien and Ceating
AII losling and oxaminalions slaII bo porformod prior
lo appIicalion of insuIalion or coalings.
7 kFkhC5
AII 510, Irossuro VossoI Inspoclion Codo: Mainlonanco
Inspoclion, Raling, Ropair, and AIloralion
16
AII 570, Iiping Inspoclion Codo: Inspoclion, Ropair,
AIloralion, and Roraling of In-Sorvico Iiping Sysloms
AII RI 2201, Safo Hol Tapping Iraclicos in llo
IolroIoum & IolroclomicaI Induslrios
IubIislor: Amorican IolroIoum Inslilulo (AII), 1220
I Slrool, NW, Waslinglon, DC 20005-4070
ASMI BoiIor and Irossuro VossoI Codo, Soclion IX
WoIding and Brazing QuaIificalions
IubIislor: Tlo Amorican Socioly of MoclanicaI
Inginoors (ASMI), Tlroo IarI Avonuo, Nov YorI,
NY 10016-5990, Ordor Doparlmonl: 22 Iav Drivo,
I.O. Box 2300, IairfioId, N} 07007-2300
NalionaI Board Inspoclion Codo, NB-23
IubIislor: Tlo NalionaI Board of BoiIor and Irossuro
VossoI Inspoclors (NBBI), 1055 Cruppor Avonuo,
CoIumbus, OH 43229

ArticIe 2.3
5eaI-weIded 1hreaded Cennectiens and
5eaI weId kepairs
1 5CkIP1I0h
1.1 Intreductien
Wloro piping sysloms, prossuro vossoIs, and procoss
oquipmonl aro assombIod by llroadod connoclions, llo
moclanicaI soaI of slandard laporod pipo llroads may
bo sufficionl for many induslriaI appIicalions. Hovovor,
somo sysloms landIing fIuids al ligl lomporaluros or
ligl prossuros, fIuids llal aro fIammabIo, loxic, or roac-
livo, or fIuids roquiring vory Iov IoaI ralos, may nol
roIy soIoIy on llroadod joinls for IoaI ligllnoss.
1.2 5eaI weIds
Wlon llo convonionco of a llroadod connoclion is
dosirod, and llo roIiabIo soaI of a voIdod connoclion is
roquirod, a soaI-voIdod llroadod joinl is somolimos
usod. SoaI voIds aro appIiod aflor llo llroads aro
ongagod. Tlo moclanicaI slrongll of llo joinl is pro-
vidod by llo llroads, vliIo llo soaI voId providos IoaI
ligllnoss.
1.3 hew 5eaI weIds Are bsed
SoaI voIds aro usod in lvo difforonl vays. Somo aro
inslaIIod in nov conslruclion, as parl of llo originaI
dosign. Ollor soaI voIds aro usod aflor conslruclion, as
a mainlonanco procoduro lo soaI llroadod connoclions
llal lavo IoaIod. IinaIIy, oIdor pIanls may lavo llroadod
connoclions llal voro pormillod in pasl spocificalions
bul nood lo bo upgradod loday by soaI voIding as parl
of an inlogrily managomonl program.
2 LIMI1A1I0h5
2.2 5peciaI Censideratiens 0utside eI 5cepe
SoaI-voIdod ropairs conduclod on-Iino, or lo sysloms
conlaining lazardous maloriaIs, may roquiro spociaI
considoralions llal aro oulsido llo scopo of llis ArlicIo.
2.3 Censideratien eI hazards
Boforo soaI voIding an oxisling llroadod connoclion,
considoralion slouId bo givon lo llo polonliaI lazard of
17
llo oxisling syslom, llo abiIily lo isoIalo llo connoclion
vliIo llo pIanl is sliII running, porsonnoI oxposuro lo
llo syslom conlonls, and llo consoquoncos of an
unscloduIod pIanl sluldovn. AIso, villoul allonlion
lo llo dolaiIs and QA/QC roquiromonls in llis ArlicIo,
soaI-voIdod llroadod connoclions aro prono lo cracIing
and IoaIago. Upon carofuI ovaIualion of lloso considora-
lions, il may bo concIudod llal a moro approprialo aclion
is lo ropIaco llo compononl(s) conlaining llo llroadod
connoclions.
2.4 PetentiaI Centaminants
Ior ropair of IoaIing llroadod connoclions, llo origi-
naI llroad soaIanl compound, llroad Iubricanl, and pro-
coss fIuid conlaminalion can maIo soaI voIding difficuIl
and rosuIl in cracIing of voIds.
2.5 weIding and MateriaI Censideratiens
Ior aII soaI voIds, carofuI ovaIualion of llo joinl is
noodod. Somo llroadod connoclions aro mado of malori-
aIs llal aro difficuIl lo voId, sucl as casl iron. }oinls may
roquiro ligl proloal, slainIoss or clromo-moIy voIding
fiIIors, or ollor spociaI voIding roquiromonls, basod on
llo maloriaIs of conslruclion and sorvico.
2.6 kemevaI eI Ceatings
Il is ossonliaI llal coalings, incIuding zinc gaIvanizing,
bo romovod from llo voId zono boforo voIding. Rocoal-
ing llo joinl aroa, aflor voIding and losling aro compIolo,
slaII bo considorod.
2.7 weIding IIect en Adjacent Cempenents
In soaI voIding of llroadod connoclions, considor-
alion slaII bo givon lo llo possibIo damaging offocls of
voIding on adjaconl compononls, sucl as sofl soals in
llroadod vaIvos.
3 5ICh
3.1 AppIicabIe Cedes
Ior ropair of originaI soaI voIds, consuIl llo originaI
codo of conslruclion, or appIicabIo posl-conslruclion
codo. Tlo roquiromonls spocifiod in paras. 3.1(a) and
3.1(b) aro from llo ASMI BIVC Soclion I, ASMI B31.1,
and ASMI B31.3, bul may bo succossfuIIy usod on any
soaI-voIdod joinl ropair.

Tlo soaI voId slaII onIy bo usod lo provido llo
lormolic soaI, nol llo moclanicaI slrongll lo llo joinl.
AII of llo romaining oxposod llroads (if any) slaII
bo compIoloIy covorod vill voId molaI.
3.2 AppIicatien te xisting [eints
Ior ropair of IoaIing llroadod connoclions llal aro
nol originaIIy soaI voIdod, il may nol bo possibIo lo
mool llo condilions of para. 3.1(a) or 3.1(b). SoaI voIds
appIiod ovor oxisling llroadod joinls may bo Ioss roIiabIo
llan nov conslruclion, so llo usor musl ovaIualo llo
safoly and roIiabiIily of oacl appIicalion individuaIIy.
3.3 [eint keassembIy
If llo joinl is disassombIod, il slaII bo roassombIod
villoul llo uso of any lapo, Iubricanls, or j oinl
compound.
3.4 1we Pass weIds
Tlo uso of lvo pass voIds ovor aII oxposod llroads
slaII bo considorod. Tvo pass voIds incroaso llo roIiabiI-
ily of llo joinl.
4 FAkICA1I0h
4.1 CIeaning
Romovo llo syslom from sorvico, and drain llo pro-
coss fIuid. MaIo llo syslom safo for lol vorI. Tlis may
bo dono by purging vill sloam, nilrogon, or ollor
inorl gas.
4.2 CIeaning eI [eints
Irior lo soaI voIding, joinls slaII bo cIoanod lo romovo
aII surfaco conlaminalion.
4.3 weIding uaIiIicatiens
WoIdors and voIding procoduros slaII bo quaIifiod
por ASMI BIVC Soclion IX, or ollor appIicabIo codo of
4.4 Fatigue Censideratiens
Ior connoclions subjocl lo vibralion or faliguo, consid-
oralion slaII bo givon lo romovaI by grinding of aII
oxposod llroads prior lo soaI voIding.
4.5 Prier 5eaI weIded [eints
Ior ropair or ropIacomonl of originaI soaI voIds
if inslaIIing ropIacomonl pipo or fillings, do nol
uso llroad soaIanl compound or Iubricanl
for ropair villoul disassombIy, llo inlogrily of llo
oId soaI voId slouId bo inspoclod visuaIIy lo dolormino
if il slouId bo compIoloIy romovod
4.6 weIding xisting Cennectiens witheut
isassembIy
Ior soaI voIding originaI llroadod connoclions vill-
oul disassombIy
18
romovo as mucl oId llroad soaIing joinl com-
pound as possibIo. A viro brusl, grindor, or lorcl may
bo noodod.
oxpocl llo IiIoIilood of porosily in llo firsl pass,
causod by burning joinl compound or lrappod fIuid
grind oul any porosily or ollor dofocls and rovoId.
Ropoal as nocossary unliI voId is IoaI ligll.
5 XAMIhA1I0h
5.1 1echniques and MethedeIegy
VisuaI oxaminalion (VT) is llo mosl common oxami-
nalion loclniquo usod for llroad soaI voIds. Magnolic
parlicIo oxaminalion (MT) or Iiquid ponolranl oxamina-
lion (IT) may bo roquirod by llo appIicabIo codo, or
may bo usod lo provido groalor assuranco of IoaI ligll-
noss. Tlo mollodoIogy slaII bo in accordanco vill llo
codo.
6 151IhC
6.1 InitiaI 5ervice 1esting
Ior mosl appIicalions, an iniliaI sorvico IoaI losl, in
vlicl llo joinls aro oxaminod for IoaIago vlon llo
syslom is rolurnod lo sorvico, is sufficionl. Wloro llo
possibiIily of IoaIago during an iniliaI sorvico IoaI losl
is unaccoplabIo, addilionaI NDI, or a lydroslalic or
pnoumalic IoaI losl slouId bo porformod prior lo pIac-
ing llo syslom in sorvico.
6.2 Leak 1esting
If groalor assuranco of IoaI ligllnoss is roquirod prior
lo sorvico, a prosorvico IoaI losl may bo usod. Oplions
incIudo bubbIo losling, pnoumalic losling, and lydro-
slalic losling.
NOTI: Tlo usor is caulionod lo considor any lazards llal migll
bo associalod vill llo losl modium (o.g., loxicily, fIammabiIily,
roaclivily, oxpIosibiIily), prossuro IovoI of fIuid, and coincidonl
slross IovoI/lomporaluro of llo compononls.
7 kFkhC5
ASMI BoiIor and Irossuro VossoI Codo, 2004 Idilion,
Soclion I Iovor BoiIors, Soclion IX WoIding and
Brazing QuaIificalions
ASMI B31.1, Iovor Iiping
ASMI B31.3, Irocoss Iiping

ArticIe 2.4
weIded Leak ex kepair
1 5CkIP1I0h
A voIdod IoaI box consisls of an oncIosuro usod
lo soaI off or roinforco a compononl. An oxampIo of a
IoaI box is iIIuslralod in Iig. 1.
IoaI boxos aro commonIy usod lo soaI ropair-
IoaIing compononls or roinforco damagod compononls.
IoaI ropair boxos can lavo a varioly of slapos
(o.g., cyIindricaI, roclanguIar, vill oillor fIal or formod
loads), oflon foIIoving llo conlour of llo pipo or compo-
nonl boing ropairod. IoaI ropair boxos can aIso bo usod
lo oncIoso compononls sucl as fIangos and vaIvos or
fillings, branclos, nozzIos or vonls and drains.
IoaI ropair boxos aro lypicaIIy cuslom-mado by
voIding spIil pipo, pipo caps, or pIalos.
Tlo annuIar spaco bolvoon llo IoaI ropair box
and llo ropairod compononl can bo Iofl omply, or fiIIod
or Iinod vill opoxy, soaIanl, fibor, rofraclory maloriaIs,
or ollor compounds.
A IoaI box can bo nonslrucluraI (dosignod lo con-
lain IoaIs) or slrucluraI (dosignod lo roinforco and loId
logollor a damagod compononl).
Fig. 1 xampIe eI a weIded Leak ex kepair eI a 1ee
19
2 LIMI1A1I0h5
2.1 CeneraI
Iarl 1 of llis Slandard, Scopo, Organizalion, and
Inlonl, conlains addilionaI roquiromonls and Iimilalions.
Tlis ArlicIo slaII bo usod in conjunclion vill Iarl 1.
2.2 Crack kepair
NormaIIy, IoaI boxos aro usod lo conlain IoaIs al pacI-
ings, and al fIango and gasIolod joinls, or lo conlain
IoaIs (or polonliaI IoaIs) duo lo IocaI llinning. Sinco llo
IoaI box may nol provonl llo propagalion of a cracI in
llo pipo or compononl, IoaI ropair boxos slaII nol bo
usod vlon cracIs aro prosonl, unIoss
llo condilions llal Iod lo llo cracI formalion and
propagalion lavo boon oIiminalod so llal llo cracI viII
nol grov during llo pIannod Iifo of llo ropair,
a filnoss-for-sorvico assossmonl slovs llal llo
cracI grovll during llo pIannod Iifo is accoplabIo, and
llal llo cracI viII nol propagalo across llo IoaI ropair
box cIosuro voId,

llo cracI is circumforonliaI and llo ropair is a
slrucluraI IoaI box, vloro llo IoaI box and ils voIds
aro dosignod for llo caso of fuII circumforonliaI broaI
of llo pipo, or soparalion of llo cracIod compononl, or
llo IoaI box fuIIy oncapsuIalos a cracIod vonl or
drain.
2.3 uaIiIicatiens
InslaIIalion, voIding and soaIanl injoclion, vloro noc-
ossary, slaII bo porformod by porsonnoI quaIifiod undor
condilions roprosonlalivo of llo fioId appIicalion.
2.4 5aIety
IorsonnoI slaII bo avaro of lazards in voIding on
dogradod compononls, and slaII laIo llo nocossary pro-
caulions lo avoid unaccoplabIo risIs.
A lazard roviov slouId bo undorlaIon prior lo
slarling llo vorI lo addross aII crodibIo probIoms llal
couId ariso.
If llo compononl is IoaIing or las llo polonliaI
lo IoaIduringinslaIIalion, and if llo conlonls aro lazard-
ous, addilionaI procaulions slouId bo laIon and lloy
slouId bo addrossod during llo projob lazard roviov
mooling (o.g., nood for frosl air suil, olc.).
3 5ICh
3.1 MateriaIs
MaloriaIs for llo IoaI box slaII bo Iislod in llo con-
slruclion or posl-conslruclion codo, and bo compalibIo
vill llo fIuid, prossuro, and lomporaluro, vill duo con-
sidoralion for llo slagnanl condilion croalod by a IoaI
of fIuid inlo llo box. GonoraIIy, llo maloriaI of conslruc-
lion of llo IoaI box slouId bo simiIar lo llo ropairod
compononl and voIdabIo lo llo oxisling prossuro bound-
ary. Tlo IoaI box dosign and conslruclion, incIuding
maloriaI soIoclion, slaII bo dono considoring llo dolorio-
ralion modo llal Iod lo llo nood for llo ropair. Tlo IoaI
box slaII bo suilabIo for rosisling llis dolorioralion modo
for llo Iifo of llo ropair.
3.2 esign LiIe
Tlo dosign Iifo of llo ropair slaII bo basod on llo
romaining slrongll of llo ropairod compononl, llo corro-
sion rosislanco, and moclanicaI proporlios of llo IoaI
box and voIds.
3.3 FaiIure Medes
Tlo box dosign slaII considor llo polonliaI inlroduc-
lion of nov faiIuro modos in llo boxod compononl. Ior
oxampIo:
IxlornaI parls of llo ropairod compononl, nov
oncIosod by llo box, sucl as fIango boIls, can signifi-
canlIy dogrado, cracI, or corrodo if in conlacl vill llo
IoaIing fIuid.
20
Bocauso llo IoaI ropair box can bo al a Iovor lom-
poraluro llan llo compononl, condonsalion of IoaIago
gasos can croalo corrosivo offocls.
Tlo box can modify llo lomporaluro of llo compo-
nonl and Ioad lo liglor corrosion ralo, or causo dov
poinl corrosion.
Tomporaluro of oncapsuIalod boIling can incroaso
and boIling can yioId, as a rosuIl of llo conlacl vill llo
procoss fIuid or llo insuIaling offocl of llo box.
Tlo dovoIopmonl of oporal ing and rosiduaI
slrossos duo lo conslrainod difforonliaI oxpansion.
3.4 1emperature and 1eughness
Tlo IoaI box maloriaIs slaII salisfy llo minimum lom-
poraluro and, vloro appIicabIo, minimum louglnoss
3.5 esign Cenditiens
IoaI ropair boxos and allaclmonl voIds slaII bo
dosignod for dosign condilions and anlicipalod lransionl
Ioads imposod on llo ropairod pipo or compononl, foI-
Ioving llo dosign roquiromonls of llo conslruclion or
3.6 uaIiIicatien
In casos vloro lloro aro no appIicabIo dosign roquiro-
monls, llo principIos of llo appIicabIo codo of conslruc-
lion or posl-conslruclion codo slaI I bo foI Iovod.
Compononls of llo IoaI ropair box llal aro fabricalod
by maclining slandard fillings (sucl as culling-oul an
oponing in slandard pipo caps lo maIo ond piocos) slaII
bo quaIifiod by anaIysis or losling, as providod in llo
codo, and bo roinforcod if nocossary.
Tlo IoaI ropair box slaII nol bo voIdod lo llo InucIIo
rogion of ond caps or formod loads unIoss llo dosign
is quaIifiod by anaIysis or proof losling, incIuding con-
sidoralion of faliguo cycIing.
3.7 Cerresien AIIewance
Tlo dosign of llo IoaI box slaII incIudo llo appIicabIo
corrosion aIIovanco, consislonl vill llo sorvico and llo
dosign Iifo of llo ropair.
3.8 esign Leads
Tlo dosign of llo voIdod IoaI box for normaI
oporaling condilions slaII considor
llo coincidonl maximum and minimum prossuros
and lomporaluros of llo syslom, unIoss moans aro pro-
vidod lo Iimil llo prossuro in llo IoaI ropair box. Dosign-
ing llo box for a Iovor rango of dosign and oporaling
lomporaluros llan llo compononl may bo accoplabIo if
juslifiod by loal lransfor anaIysis.
Tlo voId joinl officioncy faclor assignod in dosigning
llo IoaI box slaII bo consislonl vill llo lypo and oxlonl
of voId oxaminalions.

llo Ioad imposod by llo voigll of llo IoaI ropair
box, incIuding llo onlrappod IoaIing fIuid and annuIar
spaco maloriaI.
llo offocls of oxpansion, incIuding difforonliaI
oxpansion or conlraclion, and llo offocl on llo fIoxibiIily
of llo pipo or compononl. On insuIalod Iinos and compo-
nonls llo IoaI box may aIso bo insuIalod lo minimizo
difforonliaI oxpansion.
3.9 1ransient Leads
Tlo dosign of llo voIdod IoaI box for anlicipalod
lransionl Ioads slaII considor
llrusl Ioads, in caso of fuII circumforonliaI sopara-
lion of llo pipo or compononl. Dosign for llo axiaI llrusl
rosuIling from fuII circumforonliaI soparalion may bo
vaivod, providod llo caIcuIalod romaining slrongll of
llo dogradod compononl al llo ond of llo dosign Iifo
(incIuding oxpoclod conlinuing dogradalion in sorvico)
is dolorminod lo bo sufficionl. AddilionaI roslrainls may
bo addod lo llo pipo or compononl lo roduco llo Ioads
on llo IoaI box.
vind, oarllquaIo, or fIuid lransionls (fIuid lam-
mor or Iiquid sIug), as appIicabIo.
ollor appIicabIo dosign condilions.
3.10 vents and rains
Wlon ropairing a IoaIing compononl, llo IoaI box
assombIy slouId bo dosignod vill vonls and drains lo
pormil vonling llo IoaI vliIo assombIing llo box, llon
draining llo annuIus as nocossary.
Tlo vonl or drain slouId incIudo a llroadod cap,
a fIango, or a vaIvo llal viII bo oponod during voIding
lo procIudo inlornaI prossuro buiIdup, and cIosod aflor
voIding, inspoclion, and losling. Tlis samo vonl or drain
may bo usod lo vonl or drain llo IoaI ropair box in llo
fuluro.
If IoaI soaIanl maloriaI is lo bo injoclod inlo llo
IoaI ropair box, lloso vonl and drain connoclions may
bo usod, or soparalo injoclions may bo providod.
3.11 5eund MetaI
Tlo IoaI box slaII bo sufficionlIy Iong lo oxlond lo a
sound aroa of llo ropairod compononl. Tlo compononl
lo bo ropairod slaII bo oxaminod lo onsuro llal lloro is
sufficionl vaII llicInoss al llo voId Iocalions lo avoid
burn-llrougl during voIding of llo box lo llo
compononl.
3.12 5eaIant Pressure
If using soaIanl injoclion, llo possibiIily of invard
coIIapso of llo ropairod compononl duo lo llo annuIus
prossuro of llo injoclod soaIanl slaII bo considorod.
Considoralion slouId bo givon lo off-gassing of soaI-
anl compounds as lloy curo.
21
3.13 5eaIant 5eepage
If using soaIanl injoclion, llo possibiIily and conso-
quonco of soaIanl sooping inlo llo damagod compononl
3.14 [eints
IoaIboxos ovor oxpansionjoinls, sIip joinls, baII joinls,
olc., aro spociaI casos llal slaII roquiro anaIysis of llo
Ioads in llo pipo syslom, anclors, and compononl noz-
zIos vill llo box inslaIIod, vill duo considoralion for
llormaI-inducod movomonls in oporaling and slul-
dovn condilions.
4 FAkICA1I0h
4.1 Preparatien
Tlo compononl lo vlicl llo box viII bo voIdod slaII
bo froo of Iooso corrosion doposils, dirl, painl, insuIalion,
maslics, and ollor coalings in llo vicinily of llo box-
lo-compononl voIds.
4.2 Leak ex InstaIIatien
If llo IoaI box is loo Iargo lo bo Iiflod by land,
Iifling dovicos may bo nocossary.
During inslaIIalion, caro slaII bo laIon so as nol
lo damago llo box, ospociaIIy llo voId bovoIs.
Ior smaII IoaIs, llo IoaI box may bo pIacod diroclIy
ovor llo IoaI. Iargor or liglor prossuro inslaIIalions
may roquiro llo IoaI box bo assombIod on llo compononl
lo llo sido of llo IoaI and llon sIid and voIdod ovor
llo IoaI.
4.3 weIding
Tlo voId procoduro and voIdor slaII bo quaIifiod lo
porform llo ropair undor llo appIicabIo codo of con-
slruclion or posl-conslruclion codo.
4.4 In-5ervice weIding
Tlo IoaI ropair box may bo inslaIIod and voIdod lo
llo compononl vlonoul of sorvico or, vill llo nocossary
safoly procoduros, in sorvico. Ior voIding in sorvico,
llo voId procoduro quaIificalion slaII proporIy addross
proloal lomporaluro, voId cooIing ralo, llo risI of burn-
llrougl and llo offocl of llo voIding lomporaluro on
llo slrongll of llo molaI undor sorvico condilions.
4.5 Leaking Cempenent
If llo compononl is IoaIing prior lo ropair, considor-
alion slouId bo givon lo slopping llo IoaI prior lo voId-
ing llo IoaI box.
4.6 heat 1reatment
IrovoId and poslvoId loal lroalmonl slaII conformlo
llo appIicabIo codo of conslruclion or posl-conslruclion
codo, unIoss dovialions aro juslifiod by a filnoss for sor-
vico anaIysis. Basod on llo sorvico condilions, llo nood

for provoId and poslvoId loal lroalmonl boyond llo
posl-conslruclion codo slouId bo considorod.
5 XAMIhA1I0h
5.1 uaIiIicatiens
NDI porsonnoI, oxaminalion procoduros, and accopl-
anco criloria slaII bo in accordanco vill llo appIicabIo
codo of conslruclion or posl-conslruclion codo, oxcopl
as nolod in paras. 5.2 and 5.3, and bo consislonl vill
llo joinl officioncy or joinl quaIily faclors usod in dosign.
5.2 h xemptiens
NDI confirmalion of fuII ponolralion of voIds may
bo omillod if juslifiod for llo sorvico condilions, sucl
as in caso of
Iov-caIcuIalod slrossos for normaI and anlicipalod
lransionl Ioads, for oxampIo, boIov laIf llo dosign
aIIovabIo slross al oporaling lomporaluro
vloro lloro is a Iov risI of crovico corrosion al
llo box-lo-compononl voId joinl
WoIds llal cannol bo oxaminod by radiograplic or
uIlrasonic mollods bocauso of voId goomolry slouId
bo oxaminod by Iiquid ponolranl or magnolic parlicIo
mollods, and llo joinl officioncy faclor assignod in
dosign of llo IoaI box slaII bo consislonl vill llo
mollod and oxlonl of oxaminalion.
22
5.4 vaIuatien
RosuIls of oxaminalions slouId bo ovaIualod foIIov-
ing llo criloria of llo appIicabIo codo of conslruclion or
6 151IhC
6.1 1est Pressure
Tlo dosignor slaII dolormino llo lypo of prossuro or
IoaI losl lo bo conduclod aflor inslaIIalion, on llo basis
of risI (IiIoIilood and consoquonco) of faiIuro of llo
ropairod compononl vlon prossurizing llo annuIus
bolvoon llo box and llo compononl.
6.2 1est Methed
Tlo losl may consisl of ono of llo foIIoving:
an in-sorvico IoaI losl (if llo consoquonco of an
in-sorvico IoaI oul of llo box is accoplabIo)
a lydroslalic losl if lloro is no risI of ovorloaling
llo losl valor abovo fIasling lomporaluro al almosploric
prossuro
a pnoumalic prossuro losl
a sonsilivo IoaI losl (sucl as air vill bubbIo soIu-
lion, or loIium IoaI losl)
6.3 xternaI Pressure
Tlo polonliaI for oxlornaI prossuro coIIapso of llo
carrior pipo during llo losl slouId bo considorod in
spocifying llo losl prossuro.

ArticIe 2.5
weIded Lip 5eaIs
(In the course of preparation.)
23

ArticIe 2.6
FuII ncircIement 5teeI keinIercing 5Ieeves
Ier Piping
1 5CkIP1I0h
Tlis ArlicIo appIios lo llo dosign and inslaIIalion of
fuII-oncircIomonl voIdod slooI sIoovos for piping or pipo-
Iinos. Tlo sIoovos can bo dosignod for nonprossuro con-
laining roinforcomonl or for prossuro conlaining
roinforcomonl. IuII oncircIomonl roinforcomonl sIoovos
lavo provon offoclivo in llo ropair of a vido varioly of
inlornaI and oxlornaI dofocls.
1.1 FuII ncircIement 5teeI 5Ieeve
IuII oncircIomonl slooI sIoovos consisl of a cyIindricaI
sloII pIacod around llo pipo soclion lo bo ropairod and
voIdod aIong llo lvo IongiludinaI soams, as iIIuslralod
in Iigs. 1 and 2. Tloro aro lvo lypos of sIoovos, loroin
roforrod lo as Typo A and Typo B. SIoovos can bo
mado from pipo or roIIod pIalo maloriaI.
1.1.1 1ype A 5Ieeve. Typo A sIoovo onds aro nol
voIdod circumforonliaIIy lo llo carrior pipo, as slovn
in Iig. 1. Tlo Typo A sIoovo is nol capabIo of conlaining
inlornaI prossuro bul funclions as roinforcomonl for a
dofoclivo aroa. Il is onIy usod for llo ropair of dofocls
llal aro nol IoaIing and llal aro nol oxpoclod lo grov
during sorvico, or vlon llo damago moclanism and
grovll ralo aro fuIIy undorslood.
1.1.2 1ype 5Ieeve. Typo B sIoovo onds aro voIdod
circumforonliaIIy lo llo carrior pipo, as slovn in Iig. 2.
ATypo BsIoovo is capabIo of conlaining inlornaI prossuro
bocauso llo onds aro fiIIol voIdod lo llo carrior pipo.
Typo B sIoovos can bo usod lo ropair IoaIing dofocls or
dofocls llal may ovonluaIIy IoaI and lo slrongllon pipo
laving dofocls llal roduco llo axiaI Ioad carrying capa-
biIily of llo pipo.
2 CAb1I0h5 Ah LIMI1A1I0h5
2.2 keguIatiens
Tlo piping and pipoIino roguIalions rogarding ropair
and piping and pipoIino dosign codo roslriclions rogard-
ing ropair slaII bo foIIovod.
24
2.3 Leaking eIects
Ior Typo B sIoovos vill IoaIing dofocls, spociaI con-
sidoralions slaII bo laIon lo isoIalo llo IoaI prior lo
voIding.
2.4 CycIic 0peratien
If a sIoovo ropair is appIiod lo a syslom subjoclod
lo froquonl prossuro cycIos, a faliguo ovaIualion of llo
compononl slouId bo in accordanco vill para. 3.8.
Wlon a Typo B sIoovo is subjocl lo cycIic llrougl-vaII
llormaI gradionls, a faliguo ovaIualion of llo sIoovo-lo-
pipo fiIIol voIds slouId bo conduclod lo oslabIisl llo
sorvico Iifo of llo ropair, in accordanco vill para. 3.8.
2.5 CircumIerentiaI eIects
Typo A sIoovos may nol bo approprialo for llo ropair
of circumforonliaIIy orionlod dofocls bocauso lloy viII
nol rosisl axiaI Ioads on llo pipo.
2.6 bndersIeeve Cerresien
Ior Typo AsIoovos, moasuros slaII bo laIon lo provonl
corrosion duo lo llo migralion of moisluro llrougl llo
unvoIdod onds inlo llo spaco bolvoon llo pipo and
sIoovo. Sucl moasuros may incIudo llo uso of a soaIanl
or coaling suilabIo for llo oporaling onvironmonl.
2.7 weId keinIercement
Tlo prosonco of a girll voId or IongiludinaI soam
voId laving a prominonl voId roinforcomonl may inlor-
foro vill aclioving a ligll fil-up of llo sIoovo. If il is
nocossary lo romovo llo voId roinforcomonl by grinding
lo acliovo a good fil, llo voId slaII bo oxaminod by RT
or UT prior lo grinding or llo prossuro slaII bo roducod.
Tlis oxaminalion is parlicuIarIy imporlanl vlon llo Iino
is in sorvico. AIlornalivoIy, sIoovos may bo fabricalod
vill a circumforonliaI buIgo lo bridgo llo voId, as
slovn in Iig. 3. Tlo voId rool gap slaII bo uniform
aIong Iongll, incIuding buIgo.
2.8 5Ieeve 5ize kequirements
Aroas llal do nol mool Iilnoss Ior Sorvico (IIS) crilo-
ria slouId bo fuIIy covorod by llo ropair sIoovo. Ior Typo
B sIoovos, llo ond fiIIol voIds slaII onIy bo mado in
aroas vloro sufficionl vaII llicInoss oxisls lo provonl
burn-llrougl.

Fig. 1 1ype A 5Ieeve
2.9 weIding
WoIds slaII bo inslaIIod by quaIifiod voIdors in accor-
danco vill quaIifiod procoduros rofIocling acluaI fioId
condilions.
2.10 weId FiIIer MetaI
If a lardonabIo fiIIor maloriaI is usod bolvoon llo
sIoovo and carrior pipo, il slaII bo compalibIo vill llo
inlondod appIicalion. Tlo maloriaI slaII bo suilabIo for
llo sorvico lomporaluro and, for Typo B sIoovos, compali-
bIo vill llo fIuid. IiIIor maloriaI may bo appIiod prior
lo sIoovo inslaIIalion or pumpod in bolvoon llo sIoovo
and carrior pipo annuIus aflor llo sIoovo is in pIaco.
3 5ICh
3.1 1ype A 5Ieeves
Typo A sIoovos slaII bo fabricalod or manufaclurod
from slooI mooling llo maloriaI spocificalions of llo
conslruclion codo, and slouId lavo a llicInoss oquaI
25
lo al Ioasl lvo-llirds llo llicInoss of llo carrior pipo.
Tlo carrior pipo IongiludinaI slrossos slaII mool llo
roquiromonls of llo appIicabIo conslruclion codo.
3.2 1ype 5Ieeves
Typo B prossuro conlaining sIoovos slaII lavo a vaII
llicInoss oquaI lo or groalor llan llo vaII llicInoss
roquirod for llo maximum aIIovabIo dosign prossuro or,
if roquirod by llo onginooring dosign, llo fuII oquivaIonl
slrongll of llo pipo boing ropairod. Ior ligll-filling
sIoovos, llo onginooring dosign slaII bo basod on llo
nominaI vaII llicInoss of llo carrior pipo. A Iongiludi-
naI voId joinl officioncy faclor of 0.8 slaII bo appIiod
vlon caIcuIaling llo roquirod llicInoss unIoss llo voId
is 100 oxaminod by uIlrasonic oxaminalion, in vlicl
caso a joinl officioncy faclor of 1.0 may bo appIiod. If llo
Typo B sIoovo is inlondod lo provido axiaI roinforcomonl,
sucl as al a dofoclivo girll voId, il slaII bo dosignod
lo carry axiaI and bonding Ioads acling al llo sIoovo
Iocalion.

Fig. 2 1ype 5Ieeve

Fig. 3 weIded 5pIit 5Ieeve Ier bse
0ver a Cirth weId

26

Fig. 4 1ype 5Ieeve FiIIet weId 5ize Ier 5Ieeve 1hickness Less 1han er quaI te 1.4 1imes the
Carrier Pipe 1hickness

3.3 Pressure esign
Tlo prossuro dosign caIcuIalions of llo appIicabIo con-
slruclion codo slaII appIy for caIcuIaling llo roquirod
sIoovo llicInoss. SIoovo maloriaI and aIIovabIo dosign
slross slaII compIy villllo appIicabIo conslruclion codo
roquiromonls. Corrosion aIIovancos appIiod slaII bo in
accordanco vill llo onginooring dosign.
3.4 5Ieeve imensiens
Typos A and B sIoovos slaII bo al Ioasl 100 mm (4 in.)
Iong and oxlond boyond llo dofocl by al Ioasl 50 mm
(2 in.).
3.5 1ype 5Ieeve FiIIet weIds
Tlo fiIIol voId Iog sizo for circumforonliaI ond voIds
for a Typo B sIoovo slaII bo as foIIovs:
A compIolo fiIIol voId if llo sIoovo llicInoss is
Ioss llan or oquaI lo 1.4 limos llo nominaI carrior pipo
vaII llicInoss, as slovn in Iig. 4.
If a Typo B sIoovo is llicIor llan 1.4 limos llo
nominaI carrior pipo vaII llicInoss, llo circumforonliaI
onds of llo Typo B sIoovo slouIdbo clamforod al approx-
imaloIy 45 dog, dovn lo 1.4 limos llo carrior pipo nomi-
naI vaII llicInoss pIus llo gap spacing, as slovn in
Iig. 5.
Tlo loo of llo voId on llo carrior pipo slaII smoollIy
lransilion from llo carrior pipo lo voId in ordor lo mini-
mizo llo IovoI of slross inlonsificalion. Tlo incIudod
angIo bolvoon llo voId loo and llo carrior pipo slaII
nol croalo a slarp nolcl, and dofocls sucl as undorcul
aro nol aIIovod.
3.6 xternaI Prssure
IxlornaI prossuro Ioading of llo pipo villin Typo B
sIoovos slouId bo considorod by llo onginooring dosign.
Iilling llo sIoovo as ligllIy as possibIo lo onsuro Ioad
lransfor from llo pipo lo llo sIoovo slouId minimizo
llo annuIus voIumo. If llis is nol possibIo, llo annuIus
27
voIumo slouId bo fiIIod vill lardonabIo fiIIor maloriaI
(soo para. 2.9) or llo prossuro slouId bo baIancod by
lol-lapping llo pipo undor llo sIoovo. A vonl or drain
may bo providod in llo dosign. If llo annuIus is lo bo
Iofl unfiIIod, il slouId bo vorifiod llal llo slagnanl fIuid
bolvoon llo sIoovo and llo carrior pipo viII nol causo
corrosion.
3.7 xternaI amage
If oxlornaI damago is ropairod vill a Typo A or Typo B
sIoovo, llo damago slaII bo fiIIod vill a lardonabIo fiIIor
maloriaI vill comprossivo slrongll adoqualo lo lransfor
llo Ioad lo llo sIoovo. Tlo uso of a lardonabIo maloriaI
slouId bo appIiod lo fiII voids or cavilios prosonl
bolvoon llo Typo B sIoovo and llo carrior pipo.
3.8 CycIic 0peratien
If llo syslom is subjoclod lo groalor llan 400 pros-
suro cycIos, vloro llo clango in prossuro, during a cycIo,
oxcoods 20 of llo dosign prossuro, llon a dolaiIod
faliguo anaIysis of llo compononl, considoring fil-up
of llo sIoovo lo llo innor pipo, slaII bo porformod in
accordanco vill AII RI 579/ASMI IIS-1.
If a Typo B sIoovo is subjoclod lo clangos in lom-
poraluro vloro llo difforonco in moan molaI lompora-
luro bolvoon llo sIoovo and innor pipo is Ioss llan 100I
and llo numbor of cycIos is Ioss llan 200, llon a faliguo
anaIysis is nol roquirod, ollorviso a dolaiIod faliguo
ovaIualion of llo compononl, considoring fil-up of llo
sIoovo lo llo innor pipo, slaII bo porformod in accor-
danco vill AII RI 579/ASMI IIS-1.
3.9 kestraint eI Pipe uIging
IocaI vaII llinning or damago dofocls, sucl as donls,
voaIon llo carrior pipo and lypicaIIy buIgo oulvard
prior lo faiIuro undor incroasing prossuro. Tlo offoclivo-
noss of ropair sIoovos roIios on lloir capabiIily lo roslrain
llo oulvard buIging of a pipo dofocl prior lo ils faiIuro.
Tlo dosign slaII considor if il is nocossary

Fig. 5 1ype 5Ieeve FiIIet weId 5ize Ier 5Ieeve 1hickness Creater 1han 1.4 1imes the Carrier Pipe 1hickness

lo uso a lardonabIo fiIIor maloriaI (opoxy or oquiv-
aIonl) undor llo sIoovo lo fiII llo voids vlon llo dofocl
is oxlornaI
lo roduco llo Iino prossuro al limo of inslaIIalion
3.10 1ype A 5Ieeve FiIIer MateriaI
Ior Typo A sIoovos, il is nocossary lo acliovo inlimalo
conlacl bolvoon llo pipo and llo sIoovo al llo Iocalion
of llo dofocl boing ropairod and an approprialo fiIIor
maloriaI slouId bo usod lo onsuro llal llo sIoovo pro-
vidos llo dosirod prossuro Ioad roinforcomonl.
3.11 iIIerentiaI 1hermaI xpansien
DifforonliaI llormaI oxpansion bolvoon llo carrior
pipo and llo roinforcing sIoovo slaII bo considorod in
llo dosign and appIicalion of boll Typo A and Typo B
sIoovos.
4 FAkICA1I0h
4.1 InstaIIatien
Ior inslaIIalion of a Typo Aor Typo B sIoovo, llo onliro
circumforonco of llo carrior pipo in llo aroa lo bo covorod
by llo sIoovo slaII bo cIoanod lo baro molaI. If lardonabIo
fiII maloriaI is lo bo usod, llo fiIIor slaII bo appIiod lo
aII indonlalions, pils, voids, and doprossions. Tlo sIoovo
slaII bo fillod ligllIyaround llo carrior pipo. MoclanicaI
cIamping by moans of lydrauIic oquipmonl, drav boIls,
or ollor dovicos may bo usod lo onsuro fil. A no gap
fil slouId gonoraIIy bo acliovod, lovovor, a radiaI gap
of up lo 2.5 mm (
3
32
in.) maximum may bo aIIovod.
Ior sIoovos vill voIdod onds, voId sizo and voIdor
loclniquo adjuslmonls, sucl as bulloring passos, may
bo roquirod if llo gap is oxcossivo.
28
4.2 FiIIer MateriaIs
If a fiIIor maloriaI is usod bolvoon llo pipo and sIoovo,
caro slaII bo oxorcisod lo onsuro llal il doos nol oxlrudo
inlo llo voId aroas. Burning of llo fiIIor maloriaI during
voIding viII compromiso llo quaIily of llo voId. Ixcoss
fiIIor maloriaI slaII bo romovod prior lo voIding. Iump-
ing fiIIor maloriaI inlo llo annuIus aflor llo sIoovo las
boon voIdod in pIaco oIiminalos llis probIom, providod
llo annuIar gaps aro Iargo onougl lo aIIov llo fiIIor lo
fIov inlo aII voids.
4.3 Leaking eIects
Ior a IoaIing dofocl, llo dofocl aroa slaII bo isoIalod
prior lo voIding. Ior Iinos vill fIammabIo conlonls, llo
sIoovo slaII bo purgod vill nilrogon or ollor inorl gas
lo provonl llo formalion of a combuslibIo mixluro undor
llo sIoovo.
4.4 weIds
If circumforonliaI fiIIol ond voIds aro mado, llo
sIoovos IongiludinaI soams slaII bo bull voIdod lo fuII
ponolralion, as slovn in Iig. 2. Irovision for vonling
during llo finaI cIosuro voId slaII bo mado. Tlo voIding
procoduros for llo circumforonliaI fiIIol voIds slaII bo
suilabIo for llo maloriaIs and condilions of voId-cooIing
sovorily al llo inslaIIod Iocalion in llo piping or pipo-
Iinos, in accordanco vill llo codo of conslruclion or
posl-conslruclion codo. A Iov lydrogon voIding locl-
niquo slouId bo usod. Ior IongiludinaI voIds villoul
bacIing slrips, soo para. 4.5. If llo circumforonliaI voIds
aro nol mado, Typo A, llo IongiludinaI soams may con-
sisl of a groovo bull voId or fiIIol-voIdod Iap joinl, as
slovn in Iig. 1.

4.5 keduced Pressure
Roducing llo carrior piping or pipoIino oporaling
prossuro, and mainlaining fIov, vliIo llo ropair is boing
mado is rocommondod. Soo AII RI 2201 for rocommon-
dalions on voIding pipo in sorvico. Tlo piping or pipo-
Iinos may aIso bo laIon oul of sorvico lo maIo llo ropair,
lovovor, burn-llrougl slaII bo considorod. Rocom-
mondod prossuro during sIoovo inslaIIalion for piping or
pipoIinos is bolvoon 50 lo 80 of oporaling prossuro.
4.6 In-5ervice weIding
AII of llo aspocls for in-sorvico voIding of Typo B
sIoovo circumforonliaI and fuII ponolralion IongiludinaI
soams aro nol addrossod by llis documonl. ICC, AII,
ASMI, and ollor induslry informalion porlaining lo in-
sorvico voIding slaII bo considorod vlon pIanning in-
sorvico voIding. Al a minimum, quaIificalion of llo
voIding procoss slaII laIo inlo accounl
llo polonliaI for lydrogon-inducod cracIing in llo
loal-affoclod zono as a rosuIl of accoIoralod cooIing ralo
and of lydrogon in llo voId onvironmonl
llo risI of forming an unaccoplabIy lard loal-
affoclod zono duo lo baso molaI clomislry of llo sIoovo
and pipo maloriaIs
possibIo burn-llrougl of llo pipo
4.7 weId Precedure
Tlo voId procoduro, incIuding proloal and poslvoId
loal lroalmonl roquiromonls, and voIdor, or voIding
oporalors, slaII bo quaIifiod undor llo appIicabIo codo
of conslruclion or posl-conslruclion codo.
5 XAMIhA1I0h
5.1 visuaI xaminatien
AII sIoovo fil-ups slaII bo inspoclod prior lo voIding.
WoIds slaII bo visuaIIy oxaminod.
5.2 1ype A 5Ieeves
Ior Typo A sIoovos, llo voId rool aroa slaII bo visuaIIy
oxaminod during voIding lo vorify propor ponolralion
and fusion. Tlo IongiludinaI voIds slaII bo Iiquid pono-
lranl, magnolic parlicIo, or uIlrasonicaIIy oxaminod aflor
compIolion.
5.3 1ype 5Ieeves
Ior Typo B sIoovos, llo carrior pipo baso maloriaI slaII
bo uIlrasonicaIIy oxaminod for llicInoss, cracIs, and
possibIo Iaminalion in llo aroa vloro llo circumforonliaI
voIds aro lo bo appIiod. Sufficionl vaII llicInoss slaII
oxisl lo provonl burn-llrougl. If a bacIing slrip is nol
usod undor llo IongiludinaI voId, llo aroa undor il
slaII aIso bo uIlrasonicaIIy oxaminod prior lo voIding.
29
IongiludinaI soams slaII bo inspoclod aflor compIolion.
Tlo voId rool aroa slaII bo oxaminod during voIding
lo vorify propor ponolralion and fusion. Tlo circumfor-
onliaI fiIIol voIds slouId bo magnolic parlicIo or Iiquid
ponolranl oxaminod aflor voIding. Wloro doIayod voId
cracIing is a concorn, nondoslruclivo oxaminalion of llo
circumforonliaI fiIIol voId slouId bo porformod nol Ioss
llan 24 lr aflor voIding las boon compIolod. AIlorna-
livoIy, a voIding procoduro quaIifiod undor ligl cooIing
ralo, liglor carbon oquivaIonl (CI), and losling com-
pIolod aflor 48 lr of voIding por AII 1104 Appondix B,
20ll Idilion, slouId bo considorod.
5.4 In-Precess xaminatien
Tlo ovnor may roquiro fuII in-procoss visuaI oxami-
nalion, as doscribod in para. 344.7 of ASMI B31.3, of
llo sIoovo voId inslaIIalion. Wlon in-procoss oxami-
nalion is porformod, llo rosuIls slaII bo documonlod.
Ixaminalions slaII bo porformod by porsonnoI mooling
llo quaIificalion roquiromonls spocifiod by llo appIica-
bIo codo of conslruclion or posl-conslruclion codo.
5.5 h xaminatien
NDI oxaminalion mollods slaII bo in accordanco
vill ASMI BIVC Soclion V and accoplanco criloria in
accordanco vill llo appIicabIo codo of conslruclion or
6 151IhC
A IoaI Tosl slouId bo porformod on Typo B sIoovos
in accordanco vill para. 6(a) or (b), as roquirod by llo
ovnor.
Iorform a lydrolosl of a Typo B sIoovo by prossur-
izing llo annuIus bolvoon llo sIoovo and llo carrior
pipo, in accordanco vill llo appIicabIo conslruclion or
posl-conslruclion codo. Tlo losl prossuro slaII bo
soIoclod sucl llal llo innor pipo viII nol coIIapso duo
lo oxlornaI prossuro.
Iorform a Sonsilivo IoaI Tosl as doscribod in para.
345.8 of ASMI B31.3 or ollor rocognizod nalionaI
slandard.
7 kFkhC5
AGA, Amorican Gas Associalion, IipoIino Ropair
ManuaI Docombor 31,1994
AGA, Amorican Gas Associalion, 6ll Symposium on
Iino Rosoarcl Dofocl Ropair Irocoduros, }.I. Kiofnor
Oclobor 29, 1979
IubIislor: Amorican Gas Associalion (AGA), 400 N.
CapiloI Slrool, NW, Waslinglon, DC 20001
AII RI 579, Iilnoss-for-Sorvico
AII RI 2201, Safo Hol Tapping Iraclicos in llo
IolroIoum and IolroclomicaI Induslrios

AII Slandard 1104, WoIding of IipoIinos and RoIalod
IaciIilios
IubIislor: Amorican IolroIoum Inslilulo (AII), 1220 I
Slrool, NW, Waslinglon, DC 20005-4070
ASMI BoiIor and Irossuro VossoI Codo, Soclion V
Nondoslruclivo Ixaminalion
30
WoIding and Brazing QuaIificalions

ArticIe 2.7
FiIIet weIded Patches with keinIercing PIug weIds
1 5CkIP1I0h
Tlis ropair mollod doscribos llo soIoclion criloria,
appIicalion Iimilalions, dosign, fabricalion, oxaminalion
and loslingof fiIIol voIdod surfaco palclos vill roinforc-
ing pIug voIds lo prossuro-rolaining compononls. Simi-
Iar fiIIol voIdod surfaco palcl ropair mollods villoul
roinforcing pIug voIds aro providod in anollor ArlicIo
of llis Slandard.
Tlis ropair mollod consisls of filling a ropair pIalo
lo cIosoIy malcl llo originaI compononls oxlorior or
inlorior surfaco. Tlo ropair pIalo is sizod lo covor llo
aroas oxlibiling damago, boll al llo limo of ropair and
llal anlicipalod for llo ropairs dosign Iifo.
Tlo ropair mollod is lypicaIIy appIiod lo
prossuro-rolaining sloIIs llal lavo sufforod IocaI vaII
llinning (incIuding llrougl-vaII) duo lo orosion, corro-
sion, and ollor IocaI damago moclanisms.
Tlis ropair mollod is appIicabIo lo cyIindricaI,
sploricaI, fIal, andconicaI sloIIs as voII as ollor prossuro
compononls.
Tlis ropair mollod is gonoraIIy suilabIo for sorvico
lomporaluros abovo llo niI-ducliIily lomporaluro of llo
maloriaIs of conslruclion up lo a maximum dosign lom-
poraluro of 345C (650I). Uso of llis ropair mollod for
Iovor lomporaluros roquiros ovaIualion of nolcl lougl-
noss, nonducliIo fracluro and ollor appIicabIo Iov lom-
poraluro offocls. Uso of llis ropair mollod for liglor
lomporaluros roquiros ovaIualion of llormaI faliguo,
croop, and ollor appIicabIo ligl lomporaluro offocls.
Iiguro 1 slovs a lypicaI appIicalion on a vossoI
vill a noarby slrucluraI disconlinuily (in llis caso a
nozzIo). Tlo pIan viov on lop slovs lvo of many possi-
bIo ropair palcl configuralions, vlicl aro gonoraIIy roc-
liIinoar in slapo vill roundod cornors. Tlo bollom
soclionaI viov slovs llo curvaluro malcling aspocl of
oacl ropair pIalo.
2 LIMI1A1I0h5
Inlonl conlains addilionaI roquiromonls and Iimila-
lions. Tlis ArlicIo slaII bo usod in conjunclion vill
Iarl 1.
Tlis ropair mollod is nol Iimilod by llo compo-
nonl sizo. Hovovor, a sIoovo lypo ropair may bo moro
suilabIo for lloso appIicalions vloro axisymmolric
bolavior is imporlanl.
31
Tlis ropair mollod slaII nol bo usod for IollaI
sorvico appIicalions or vloro llo damago moclanism,
llo oxlonl of damago, or IiIoIy fuluro damago cannol
bo claraclorizod. Tlis ropair mollod may bo usod in
corl ain casos on aroas vill IocaI cracI-IiIo fIavs
providod
llo grovll las sloppod, boon arroslod, or can
bo accuraloIy prodiclod for aII propagalion modos, and
llo offocl of llo fIav is ovaIualod using dolaiIod
anaIysos.
3 5ICh
3.1 CeneraI
Tlo dosign approacl for llis ropair mollod is
basod in parl on slandard prossuro compononl dosign
caIcuIalions, sucl as lloso in llo ASMI BIV Codo,
Soclion VIII, Division 1. Tlo appIicalion Iimilalions
imposod in soclion 2 appIy lo llo govorning Ioad caso
rosuIling from inlornaI prossuro vloro llo rosuIlanl
slross is mombrano slross. Hovovor, if llo compononl
lo bo ropairod is subjocl lo bonding, lorsion, vind Ioads,
or lo faliguo, llo dosign slaII incIudo ovaIualion of lloso
condilions using approprialo mollods of anaIysis. In aII
casos, an onginooring anaIysis slaII bo porformod.
In gonoraI, llo palcl maloriaI and voIding fiIIor
molaI slouId bo llo samo or vory simiIar (o.g., composi-
lionaI, plysicaI, and moclanicaI proporlios) lo llal of
llo prossuro compononls originaI conslruclion. Ropair
maloriaI soIoclion slaII considor, as a minimum, clarac-
lorislics sucl as clomislry, voIdabiIily, plysicaI propor-
lios (sucl as coofficionl of llormaI oxpansion),
moclanicaI proporlios (sucl as slrongll, ducliIily, nolcl
louglnoss), and compalibiIily vill llo procoss modium.
Tlo llicInoss of llo palcl pIalo is dopondonl on
maloriaI moclanicaI proporlios and llo caIcuIalod
allaclmonl voId sizos.
Tlo sizo (Iongll and vidll) of llo palcl pIalo is
govornod by llo roquiromonl llal aII allaclmonl voIds
bo Iocalod on sound baso molaI compIoloIy oncom-
passing llo damagod aroa(s) (soo Iig. 1). Tlo ropair pIalo
slaII aIso bo Iargo onougl lo oncompass any addilionaI
aroa(s) anlicipalod lo oxporionco simiIar or roIalod dam-
ago during llo Iifo of llo ropair. Tlo palcl pIalo, incIud-
ing roinforcing pIug voIds, slouId ovorIap sound baso
molaI by al Ioasl 25 mm (1 in.).
(08)

Fig. 1 1ypicaI 5heII kepair hear iscentinuity

32

Tlis ropair mollod is gonoraIIy usod on llo oul-
sido surfaco of compononls subjocl lo inlornaI prossuro.
Ior appIicalions undor oxlornaI prossuro, a soparalo
anaIysis lo ovaIualo bucIIing and ollor inslabiIily con-
sidoralions slaII bo porformod.
In assossing llo appIicabiIily and sorvico Iifo of llis
ropair mollod, considoralion slaII bo givon lo maloriaI
compalibiIily, fuluro oporaling condilions, llormaI and
slrinIago offocls of voIding, llo inlroduclion of crovicos
and slrucluraI disconlinuilios, llormaI lransionls and
lomporaluro difforonliaIs bolvoon llo palcl pIalo and
llo compononl, and ollor appIicalion Iimils sucl as
oxaminalion and losling conslrainls. If llo damago lo
bo palclod is, or is oxpoclod lo bo, llrougl-vaII, llo
offocls of fIuids (o.g., onlrapmonl, conconlralion, corro-
sion, olc.) llal may accumuIalo bolvoon llo vossoI and
llo palcl pIalo slaII bo assossod. If llis ropair mollod
is lo bo impIomonlod during compononl oporalion, addi-
lionaI procaulions may nood lo bo laIon for porsonnoI
safoly.
Tlo dosign may considor llo combinod slrongll
of llo palcl pIalo and llo undorIying sloII, laIing inlo
accounl llo slrongll of llo fiIIol voId and pIug voId
joinls, incIuding joinl officioncy. Considoralion may aIso
bo givon lo oxcoss llicInoss avaiIabIo adjaconl lo llo
damagod sloII using appIicabIo codo aroa ropIacomonl
ruIos for nozzIos. No crodil slaII bo laIon for maloriaI
roquirod for fuluro corrosion aIIovanco.
3.2 InternaI Pressure Leads
Ior cyIindricaI compononls subjocl lo inlornaI
prossuro Ioads, appIiod forcos on llo ropair palcl slaII
bo dolorminod as foIIovs:
Unil forcos in loop
diroclion:
2
(1)
vloro
diamolor al mid-vaII of compononl, mm (in.)
circumforonliaI forco duo lo inlornaI prossuro,

N/mm (Ib/in.)
inlornaI dosign prossuro, IIa (psi)
33
Unil forcos in IongiludinaI
diroclion:
4
(2)
vloro
IongiludinaI forco duo lo inlornaI prossuro,

N/mm (Ib/in.)
If ollor Ioads aro appIicabIo (sucl as bonding,
lorsion, vind, olc.), lloy slaII bo dolorminod and addod
lo llo prossuro Ioad sucl llal
and
vloro
lolaI circumforonliaI forco from aII Ioads,

N/mm (Ib/in.)
circumforonliaI forco duo lo ollor appIicabIo

Ioads, N/mm (Ib/in.)
lolaI IongiludinaI forco from aII Ioads, N/mm

(Ib/in.)
IongiludinaI forco duo lo ollor appIicabIo

Approprialo aIlornalivo forco caIcuIalions for
sploricaI, lorisploricaI, or oIIipsoidaI prossuro compo-
nonls slaII bo usod vlon appIicabIo.
3.3 5tructuraI iscentinuity vaIuatien
Ior slrossos noar a nozzIo or ollor slrucluraI dis-
conlinuily lo bo insignificanl, llo minimum dislanco
bolvoon llo fiIIol voIdod palcl pIalo and llo oxisling
disconlinuily slouId bo
min
2(
)
1/2
(3)

vloro
min
pIalo sol-bacI dislanco (soo Iig. 1), mm (in.)
radius al mid-vaII of compononl, mm (in.)

vaII llicInoss of compononl, mm (in.)
Tlo faclor of 2 appIios llo sol-bacI dislanco (
)
1/2
lo boll llo oxisling nozzIo (or ollor simiIar slrucluraI
disconlinuily) and llo palcl pIalo.
Tlis proximily Iimil aIso appIios lo llo dislanco
bolvoon adjaconl fiIIol voIdod palcl pIalos, in lloso
appIicalions vloro moro llan ono is ompIoyod on a
givon compononl.
In lloso appIicalions vloro llo palcl pIalo is lo
allacl lo oxisling nozzIo roinforcomonl pads, llo palcl
pIalo may bo conlourod lo malcl llo roinforcomonl pad
porimolor and voIdod llorolo vill a fuII ponolralion
joinl.
In lloso appIicalions vloro llo damagod sloII is
villin
min
of a nozzIo or ollor slrucluraI disconlinuily,
llo palcl pIalo slouId bo dosignod as a roinforcomonl
pad oxlonding 360 dog around llo nozzIo/oponing, and
voIdod llorolo vill a fuII ponolralion joinl. AIlorna-
livoIy, addilionaI dolaiIod anaIysis slaII bo porformod
lo ovaIualo IocaI slrossos.
3.4 AIIewabIe Lead en Perimeter FiIIet weId
Tlo porimolor voId slaII bo sizod sucl llal llo
aIIovabIo Ioad on llo voId oxcoods llo IongiludinaI and
circumforonliaI Ioads.

min
(4)
vloro
voId joinl officioncy faclor (0.55)
aIIovabIo forco on fiIIol voIds, N/mm

(Ib/in.),
and
aIIovabIo baso molaI slross, MIa (psi)

1
min
minimum voId Iog dimonsion, mm (in.)
NOTI: Tlo maximum dosign fiIIol voId sizo slaII nol oxcood llo
llicInoss of llo llinnor maloriaI boing joinod nor 40 mm (1.5 in.).
AIlornalivoIy, llo porimolor voId odgo propara-
lion may bo bovoIod lo incroaso llo voIds offoclivo
llroal llicInoss. In no caso slaII llo offoclivo llroal
oxcood llo llicInoss of llo ropair pIalo or llo originaI
compononl llicInoss.
3.5 AIIewabIe Leads en PIug weIds
IIug/sIol voIds may bo dosignod lo laIo up lo
30 of llo palcl pIalo Ioad. Tlo aIIovabIo vorIing Ioad
1
CompalibIo voId molaI slaII bo of oquaI or groalor slrongll.
34
on a circuIar pIug voId in oillor sloar or lonsion slaII
bo dolorminod by

0.63
(
2
(5)

0.63
(
2
And llo aIIovabIo vorIing Ioad on a sIol voId slaII
bo dolorminod by

0.8
|(
2
] (6)

0.8
|(
2
]
vloro
llo bollom diamolor of llo loIo in vlicl llo
voId is mado, mm (in.)
lolaI aIIovabIo vorIing Ioad on llo pIug

voId, N (Ib)
lolaI aIIovabIo vorIing Ioad on llo sIol

voId, N (Ib)
llo bollom Iongll of llo sIol in vlicl llo voId
is mado, mm (in.)
llo radius of llo sIol onds in vlicl llo voId
is mado ( /2), mm (in.)
llo bollom vidll of llo sIol in vlicl llo voId
is mado, mm (in.)
IIug voIds aro roquirod in aII casos lo minimizo
slross al llo rool of llo porimolor fiIIol voIds andaddross
Ioad pall occonlricily considoralions in llo porimolor
voIds. IIug voId loIos slouId lavo a diamolor nol Ioss
llan + 6 mm (
1
4
in.) and nol moro llan 2 + 6 mm
(
1
4
in.). IIug voIds slaII bo sol bacI from llo odgo of
llo palcl pIalo by nol Ioss llan 2 nor moro llan 4.
IIug voIds slouId bo spacod lo carry lloir proporlion
of llo Ioad, bul lloir pilcl (conlor-lo-conlor spacing)
slouId nol bo Ioss llan 3.
IIug voId loIos slouId bo compIoloIy fiIIod vill
voId molaI vlon llo llicInoss of llo palcl pIalo () is
8 mm (
5
16
in.) or Ioss, for palcl pIalos vloro 8 mm
(
5
16
in.), llo loIos slouId bo fiIIod lo a dopll of al Ioasl
1
2
or
5
16
of llo loIo diamolor, vliclovor is Iargor, bul
in no caso Ioss llan 8 mm (
5
16
in.).
Ior pIug voIds smaIIor llan 19 mm (
3
4
in.) diamo-
lor, sIollod or obround pIug voIds may bo usod lo mini-
mizo voId quaIily difficuIlios arising from accossibiIily
and oIoclrodo manipuIalion conslrainls. SIol voIds
slouId lavo a vidll nol Ioss llan + 6 mm (
1
4
in.) nor
groalor llan 2 + 6 mm (
1
4
in.), and a Iongll nol moro
llan 3 + 6 mm (
1
4
in.). Tlo Iong axis of sIol voIds slaII

bo orionlod porpondicuIar lo llo adjaconl fiIIol voIdod
odgo. Sol-bacI and spacing slaII mool llo roquiromonls
of para. 3.5(b).
3.6 CeId Ferming Limits
Carbon and Iov aIIoy slooI palcl pIalos fabricalod
by coId forming slaII nol oxcood 5 oxlromo fibor oIon-
galion. Tlo oxlromo fibor oIongalion slaII bo dolorminod
as foIIovs:
Ior doubIo curvaluro
75
5 (7)
vloro
finaI conlorIino radius of palcl pIalo, mm (in.)
originaI conlorIino radius of palcl pIalo (oquaIs

infinily for fIal pIalo), mm (in.)
llicInoss of llo palcl pIalo, mm (in.)
Ior singIo curvaluro
50
5 (8)
Ialclos coId formod boyond lloso Iimils may bo
usod providod lloy rocoivo approprialo posl-forming
slross roIiof prior lo inslaIIalion.
4 FAkICA1I0h
IIalo odgos may bo cul lo slapo and sizo by
moclanicaI moans sucl as maclining, sloaring, grind-
ing, or by llormaI moans sucl as fIamo or arc culling.
If llormaI moans aro usod, a minimumof 1.5 mm(
1
16
in.)
addilionaI maloriaI slaII bo romovod by grinding or
maclining. If llo ropair pIalo is groalor llan 25 mm
(1 in.) llicI, and llo fiIIol voId sizo is Ioss llan llo pIalo
llicInoss, llo voId prop odgos slaII bo oxaminod by
magnolic parlicIo (MT) or Iiquid ponolranl (IT) mollods
lo clocI for Iaminalions. Iaminalions slaII bo causo for
rojoclion unIoss ropairod or found accoplabIo by
filnoss-for-sorvico anaIysis in accordanco vill
AII 579-1/ASMI IIS-1.
IIug or sIol voId loIos may bo fabricalod by
puncling, driIIing, maclining, or fIamo/arc culling. Tlo
onds of sIol voIds, if usod, slaII lavo a radius, , oquaI
lo ono-laIf llo sIols vidll, . If llormaI moans aro
usod, a minimum of 1.5 mm (
1
16
in.) addilionaI maloriaI
slaII bo romovod by grinding or maclining. If llo ropair
pIalo is groalor llan 25 mm (1 in. ) llicI, and llo
pIug/sIol voId sizo is Ioss llan llo pIalo llicInoss, llo
voId prop odgos slaII bo oxaminod by magnolic parlicIo
(MT) or Iiquid ponolranl (IT) mollods lo clocI for Iami-
nalions. Iaminalions slaII bo disposilionod as spocifiod
in (a) abovo.
Tlo palcl pIalo may bo formod lo llo roquirod
slapo by any procoss llal viII nol unduIy impair llo
35
moclanicaI proporlios of llo palcl pIalo maloriaI. Wloro
roquirod duo lo ropair pIalo sizo or accoss/inlorforonco
considoralions, spIil soclions may bo usod vlon joinod
by fuII ponolralion voIds.
Iarls lo bo fiIIol voIdod slaII bo fil as ligllIy as
praclicaI lo llo surfaco lo bo voIdod and in no ovonl
slaII bo soparalod by moro llan 5 mm (
3
16
in.). If llo
soparalion al llo faying odgo of llo pIalo is 1.5 mm
(
1
16
in.) or groalor, llo sizo of llo porimolor fiIIol voId
slaII bo incroasod by llo amounl of llo soparalion.
WoIding procoduros, voIdors and voIding opora-
lors slaII bo quaIifiod in accordanco vill llo curronl
posl-conslruclion codo. If nol ollorviso spocifiod, ASMI
BIV Codo, Soclion IX may bo usod for procoduro and
porformanco quaIificalion. Guidanco for proloal and/
or poslvoId loal lroalmonl, and for in-sorvico voIding,
as appIicabIo, slaII bo laIon from llo appIicabIo codo
IioId ropair aclivilios slouId conform lo llo foI-
Ioving soquonco:
Iainl, scaIo, rusl, Iiquids and ollor foroign malo-
riaI slaII bo romovod from llo voId zono and an aroa nol
Ioss llan 40 mm (1
1
2
in.) on oillor sido of llo voIdmonl.
In lloso aroas llal viII bo covorod by llo nov
palcl pIalo, oxisling sloII soam or girll voIds slaII bo
ground fIusl vill llo vossoI or pipo O.D. and slaII bo
oxaminod by llo MT or IT mollod.
Tlo nov palcl pIalo may bo pIacod in posilion
using any suilabIo mollod.
Any soams villin llo palcl ilsoIf, slouId bo
mado firsl. Tlo porimolor fiIIol voId may llon bo com-
pIolod. CIamps or vodgos may bo usod lo onsuro propor
joinl aIignmonl and fil-up.
Ixposod molaI surfacos slaII bo rocoalod, if appIi-
cabIo, aflor compIolion of aII oxaminalion and losling.
To procIudo gas prossuro buiIdup bolvoon llo
palcl pIalo and llo prossuro compononl boundary, pro-
visions for vonling during llo finaI cIosuro voId or, if
appIicabIo, poslvoId loal lroalmonl, may bo nocossary.
If llo palcl pIalo is dosignod for llrougl-vaII dofocls
bul appIiod lo llo prossuro boundary boforo boing
broaclod, llo vonl slouId bo soaIod aflor compIolion of
voIding and, if appIicabIo, poslvoId loal lroalmonl.
5 XAMIhA1I0h
Ialcl pIalo allaclmonl voIds slaII bo oxaminod
in accordanco vill llo appIicabIo codo of conslruclion
or posl-conslruclion codo by oillor llo MT or IT moll-
ods. If nol ollorviso spocifiod by llo appIicabIo codo
of conslruclion or posl-conslruclion codo, NDI slaII bo
porformod using procoduros vrillon and quaIifiod in
accordanco vill ASMI BIVC Soclion V.
If Iifling Iugs aro usod and Iofl in pIaco, lloir
allaclmonl voIds slaII bo oxaminod by MT or IT moll-
ods. Al aII Iocalions vloro lomporary Iifling Iugs,

voIdod cIamps, and/or vodgos aro romovod aflor palcl
pIalo inslaIIalion, llo romovaI aroas slaII bo oxaminod
by MT or IT mollods.
WoIds joining soclions of palcl pIalos mado of
soparalo piocos slouId bo surfaco conlourod and voIu-
molricaIIy oxaminod by oillor radiograplic or uIlrasonic
oxaminalion mollods lo llo oxlonl possibIo. If nol pracli-
cabIo, muIli-Iayor IT or MT oxaminalions slouId bo
porformod.
If poslvoId loal lroalmonl is roquirod, llo oxami-
nalion slaII bo porformod aflor appIicalion of IWHT.
Tlo oxaminalion accoplanco criloria of llo appIica-
bIo codo of conslruclion or posl-conslruclion codo slaII
appIy.
6 151IhC
Tosling slaII bo porformod in accordanco vill llo
Tlo prossuro compononl and inslaIIod palcl
pIalo(s) slouId bo IoaI loslod in accordanco vill llo
appIicabIo posl-conslruclion codo. SpociaI safoly procau-
lions slouId bo laIon vlon pnoumalic IoaI losling is
porformod.
If pormillod by llo appIicabIo posl-conslruclion
codo, nondoslruclivo oxaminalion may bo porformod as
36
an aIlornalivo lo IoaI losling. AIso, an iniliaI sorvico
inspoclion may bo porformod of aII voId joinls aflor llo
prossuro compononl las rolurnod lo normaI oporaling
prossuro and lomporaluro.
Tosling andinspoclions slouIdbo porformod prior
lo roappIicalion of coaling, insuIalion, or jacIoling, as
appIicabIo.
7 kFkhC5
AII 579-1/ASMI IIS-1, Iilnoss-for-Sorvico, }uno 5, 2007
Slrool NW, Waslinglon, DC 20005-4070
ASMI BoiIor and Irossuro VossoI Codo, Soclion VIII,
Division 1 RuIos for Conslruclion of Irossuro
VossoIs
ASMI BoiIor and Irossuro VossoI Codo, Soclion IX,
QuaIificalion Slandard for WoIding and Brazing
Irocoduros, WoIdors, Brazors, and WoIding and
Brazing Oporalors
Inginoors (ASMI), Tlroo IarI Avonuo, NovYorI, NY
10016-5990, Ordor Doparlmonl: 22 IavDrivo, I.O. Box
2300, IairfioId, N} 07007-2300

ArticIe 2.8
AIternatives te 1raditienaI weIding Preheat
1 5CkIP1I0h
Iroloaling invoIvos loaling piocos lo bo voIdod lo
somo lomporaluro abovo lloir ambionl lomporaluros
prior lo and during voIding. Conslruclion and
posl-conslruclion codos oflon roquiro proloal. Hovovor,
undor corlain condilions il may bo possibIo lo uso ollor
aIlornalivos lo proloal. Wlollor proloal is roquirod or
nol, proloal can provido any combinalion of llo foIIov-
ing bonofils:
roduco slrinIago slrossos in llo voId and adjaconl
baso molaI, ospociaIIy in liglIy roslrainod joinls
provido a sIovor ralo of cooIing llrougl llo crili-
caI lomporaluro rango, provonling oxcossivo lardoning
and roducod ducliIily of boll llo voId and loal-affoclod
zono (HAZ)
provido a sIovor ralo of cooIing llrougl llo 400I
rango, aIIoving moro limo for lydrogon llal may bo
prosonl lo diffuso avay from llo voId and adjaconl baso
molaI lo avoid lydrogon cracIing
Considoralions sucl as llo prosonco of noarby coal-
ings or ollor compononls can maIo proloal roquirod by
llo originaI conslruclion codo inadvisabIo or impraclicaI
lo appIy. Hovovor, if voIding loal inpuls noar llo maxi-
mum aIIovod by llo quaIifiod procoduros aro usod, loal
llal is lransforrod lo llo mass of llo assombIy may bo
baIancod by llo voIding loal inpul, rosuIling in llo
affoclod molaI boing loalod up lo or boyond llo mini-
mum proloal roquiromonl, lloroforo pormilling roIaxod
appIicalion of proloal from oxlornaI moans. Tlis ArlicIo
considors appIicalion of aIlornalo proloal slralogios or
aIlornalivos lo lradilionaIIy spocifiod proloal llal migll
bo pormillod by carofuI soIoclion and conlroI of llo voId-
ing procoss, consumabIos, andloclniquo suclas by voId
boad soquoncing.
2 LIMI1A1I0h5
2.1 CeneraI
2.2 Prehibited keductien
Roduclion in proloal may aIso bo prolibilod by usor
roquiromonls, sorvico condilions, or conslruclion codos.
37
2.3 Inapprepriate Cases
Roducing proloal may nol bo approprialo in many
casos. Sucl silualions incIudo maloriaIs vill oIovalod
carbon conlonl or carbon oquivaIonl, ligl lardonabiIily
and/or goomolrios vill ligl roslrainl.
2.4 Limited Access
Iimilod accoss may provonl llo uso of loclniquos or
voIding procossos nocossary for salisfaclory porform-
anco of voIding vill Iovor proloal.
2.5 weIding
AII voIding slaII bo in accordanco vill an appIicabIo
conslruclion or posl-conslruclion codo, incIuding voId-
ing procoduros.
3 5ICh
Tlo foIIoving slralogios and considoralions may bo
pormissibIo aIlornalivos lo llo originaI codo of conslruc-
lion or posl-conslruclion codo proloal roquiromonls:
groovo goomolry
voIding procoss
voIding consumabIos
ovaIualion of carbon oquivaIonl
ovaIualion of cracIing paramolor (Icm)
conlroIIod doposilion (lompor boad) voIding
3.1 Creeve Ceemetry
Groovo goomolry and voIumo of voId molaI slouId
bo minimizod lo roduco rosiduaI slrossos, bul nol lo llo
oxlonl llal llo abiIily lo voId is compromisod or cracI-
ing rosuIls.
Minimizo rosiduaI slrossos on voId and HAZ. Il
is difficuIl lo avoid rosiduaI slrossos vlon voIding. As
llo moIlon puddIo soIidifios, il roducos in sizo and llus
croalos rosiduaI slrossos as slovn in Iig. 1.
Tlin, vido boad slapos vill minimaI llicInoss
or cross soclion aro moro prono lo cracIing fromroducod
proloaling llan moro roundod or conicaI slapos.
WoIdod joinls vill groalor lransvorso slrinIago, as
slovn in Iig. 2, aro moro suscoplibIo lo cracIing. WoIds
llal oxlibil vidor groovo angIos and groalor voId voI-
umo normaIIy aIso oxlibil liglor IovoIs of rosiduaI
slross.
3.2 weIding Precess
WoIding procossos llal minimizo diIulion and aro
Iov lydrogon in appIicalion slouId bo considorod.
(08)

Fig. 1 1ypicaI kesiduaI 5tresses in a weId
Fig. 2 IIect eI weId Area en 1ransverse 5hrinkage

GMAW and GTAW aro parlicuIarIy voII suilod lo
conlroI diIulion and do nol lypicaIIy inlroduco lydrogon
inlo llo voId doposil. Tloso procossos slouId bo candi-
dalos vloro roducod proloal is dosirabIo.
SMAW, ICAW, or SAW may aIso bo usod vloro
incroasod doposilion and Iovor slrinIago is imporlanl.
Caro slaII bo obsorvod during quaIificalion of voIding
procoduros lo ovaIualo loal inpul and avoid paramolors
llal vouId croalo oxcossivo ponolralion, diIulion, or
slrinIago.
3.3 weIding CensumabIes
WoIding consumabIos slouId loIoralo accoIoralod
cooIing ralos (o.g., rosisl lol cracIing during cooIing),
bo Iov lydrogon by dosign (H4 or H5 aro oplimum),
and oxlibil good voIdabiIily.
Tlo uso of voIding consumabIos llal provido oquiva-
Ionl bul nol ovormalcling proporlios (Iovor slrongll,
minimizod carbon forrilics, nonforrous, olc.) slouId bo
considorod lo avoid mismalcl in slrongll IovoIs bolvoon
llo voId molaI, loal-affoclod zonos, and baso molaIs.
Mosl commorciaI voId molaI is formuIalod lo compon-
salo for diIulion and/or poslvoId loal lroalmonls undor
a varioly of condilions. Tloroforo, mosl voId molaIs
38
oxlibil slronglls mucl liglor llan lloir spocificalion
minimums. Tlis can bo vory imporlanl vlon dosigning
andimpIomonling ropair voIding. Acomparison of lypi-
caI voId molaI slronglls for soIoclod consumabIos is
slovn in TabIo 1. Wloro llis approacl is usod, acluaI
proporlios of llo voId molaI slouId bo vorifiod from
oillor corlifiod maloriaI losl roporls or roprosonlalivo
losl coupons.
3.4 Carben quivaIent
Carbon oquivaIonl (CI) may bo usod as a moans for
dolormining llo acluaI nocossily for proloal and llo
IovoI roquirod.
Wloro (Wl. ):
CI C + (Mn + Si)/6 + (Cr + Mo + V)/5 + (Ni + Cu)/15
CI 0.45, proloal is normaIIy oplionaI
0.45 CI 0.60, proloal 200I lo 400I
CI 0.60, proloal 400I lo 700I
vloro CI 0.5, doIaying finaI NDI for al Ioasl 24 lr
slouId bo considorod lo idonlify any doIayod cracIing.
3.5 Cracking Parameter (Pcm)
Wloro carbon conlonl is oquaI lo or Ioss llan 0.17 vl.
or vloro ligl-slrongll slooIs aro invoIvod, llo Ilo &
Bossyo CracIing Iaramolor (Icm) can bo usod. Tlis
approacl providos a moro accuralo prodiclion for vlon
proloal viII bo noodod, vlon proloal is mandalory, and
al vlal rocommondod lomporaluro.
Wloro |Icm in vl.]:
Icm C +
Si
30
+
Mn + Cu + Cr
20
+
Ni
60
+
Mo
15
+
V
10
+ 5B 2
Icm 0.15, proloal is normaIIy oplionaI
0.15 Icm 0.26 lo 0.28, proloal 200I lo 400I
Icm 0.26 lo 0.28, proloal 400I lo 700I

1abIe 1 Cemparisen eI 5peciIicatien and ActuaI weId MetaI Preperties

F6013 62 50 7/ 6/ . . . . . .
F6018 67 55 68 57 . . . . . .
F7018 72 60 87 79 83
(1)
7/
(1)
F7018-A1 70
(1)
57
(1)
90 71 8/
(1)
70
(1)
F8018-82 80
(2)
68
(2)
118 103 95
(1)
79
(1)
F9018-83 90
(2)
77
(2)
1/1 127 101
(1)
87
(1)
F9015-89 90
(3)
77
(3)
210 . . . 120
(/)
100
(/)
Fk70S-2 70 58 7/ 60 . . . . . .
Fk70S-6 72 60 9/
(5)
75
(5)
85
(1), (5)
71
(1), (5)
Fk80S-u2 80 68 110 79 100
(2)
86
(2)
Fk70S-A1 80
(6)
68
(6)
92 79 90
(2)
72
(2)
Fk90S-83 90
(2)
78
(2)
. . . . . . 10/
(2)
93
(2)
hUTFS:
(1) Stress relleved [ 621C (1,150F) fcr 1 hr.
(2) Stress relleved [ 690C (1,275F) fcr 1 hr.
(3) Stress relleved [ 7/6C (1,375F) fcr 1 hr.
(/) Stress relleved [ 760C (1,/00F) fcr 1 hr.
(5) 6TAw prccess.
(6) S6Mc ulh 8575, wks. hc. 1.5/2/.
3.6 CentreIIed epesitien weIding
Uso of conlroIIod doposilion (lompor boad) proco-
duros can bo usofuI lo gonoralo fino grain loal affoclod
zonos and improvo nolcl louglnoss. Tlis mollod
slouId bo considorod vlon oillor oIovalod proloal or
codo-roquirod poslvoId loal lroalmonl cannol bo usod.
RuIos for quaIificalion of procoduros aro incIudod in
AII 510, 7.2.3, ASMI IX, QW-290, and ANSI NB-23.
3.6.1 Wloro simiIar composilion voId molaI is
usod, llis mollod viII NOT Iovor rosiduaI slrossos. An
ovaIualion lo considor llo offocl of voIding rosiduaI
slrossos slouId bo conduclod vloro llis mollod is lo
bo usod.
4 FAkICA1I0h
In ordor lo uso aIlornalivo proloaling slralogios, fabri-
calion loclniquos slouId bo carofuIIy conlroIIod lo avoid
llo probIoms llal proloal vouId bo ompIoyod lo mili-
galo. WoIding procossos and consumabIos llal aro Ioss
IiIoIy lo inlroduco lydrogon can bo closon ovor ollor
oplions. Corlain loclniquos can minimizo or roduco
rosiduaI slrossos. CarofuI moniloring slouId bo dono
lo onsuro llal aIlornalivos aro ompIoyod proporIy. Tlo
foIIoving doscribo or aro imporlanl for succossfuI impIo-
monlalion of lloso loclniquos.
4.1 CIeanIiness
Conlaminanls (dirl, groaso, moisluro, olc.) slouId
aIvays bo romovod prior lo appIicalion of any voIding.
39
Fig. 3 1ypicaI ack 5tepping weId 5equence
4.2 weIding 1echnique

Tlo loclniquo usod during voIding las a significanl
offocl on slrinIago, rosuIling rosiduaI slrossos, conlroI-
Iing loal inpul, and avoiding cracIing issuos.
Slorl vorsus Iong boads lypicaIIy minimizo Iongi-
ludinaI slrinIago. BacI slopping (Iig. 3) or spociaI
soquoncing lo roduco rosiduaI slrossos may nood lo bo
ompIoyod.
ConlroI or minimizo loal inpul. Slringor boads
vill minor osciIIalion vorsus vido voavo boads slouId
bo usod. Soo Iig. 4.
4.3 Peening
Iooning can bo an offoclivo loclniquo for minimizing
slrinIago and dislorlion. Il is nol normaIIy usod or
pormillod on llo rool and finaI passos of a voId. Ior
pooning lo bo offoclivo, llo molaI slouId bo doformod

Fig. 4 iIIerence etween 0sciIIated 5tringer eads
(LeIt) and wide weave eads (kight)
and yioId. Croaling dimpIos in llo surfaco vill a noodIo
gun, olc., is NOT oquivaIonl lo pooning.
4.4 Minimizing Cracking
Cralor and voId boad cracIing can bo minimizod or
oIiminalod by impIomonling propor vorImanslip
loclniquos.
WoId boads vill round cross soclions vorsus llin,
vido boads slouId bo doposilod as slovn in Iig. 5 lo
minimizo cracIing.
Abrupl sl arl/slops slouId bo avoidod. Uso
up/dovn sIopo loclniquos vill oillor procoss manipu-
Ialion and boad slaping or via oIoclronic moans vill
llo voIding povor sourco.
Sufficionl maloriaI slouId bo doposilod lo avoid
cracIing from slrinIago and normaI conslruclion infIu-
oncos. A good ruIo of llumb lo avoid cracIing from
insufficionl voId molaI doposilod (and roquirod in many
conslruclion codos) is a minimum of 10 mm (
3
8
in.) or
25 of llo voId groovo llicInoss.
4.5 Preheat Metheds
Iroloaling may bo conduclod vill fIamo (air-fuoI or
oxy-fuoI), oIoclricaI rosislanco, or oIoclricaI induclion
mollods in boll llo slop and fioId. RogardIoss of llo
mollod, loaling slouId bo uniform and llrougl llicI-
noss unIoss ollorviso spocifiod.
4.6 Preheat Menitering
A varioly of dovicos aro avaiIabIo for moasuring and
moniloring lomporaluros. Tlo compononl or pioco boing
voIdod slouId bo proloalod lo aIIov llo loal lo soaI
inlo llo maloriaI. Wloro possibIo, llis slouId bo moni-
lorod and vaIidalod. Moniloring llo surfaco lomporaluro
a prodolorminod dislanco avay from llo voId odgo is
normaIIy adoqualo for mosl appIicalions. Il is novor
accoplabIo lo maIo or laIo roadings llal vouId rosuIl
in conlaminalion of llo voId groovo.
Tloso crayons or
ponciI-IiIo dovicos aro dosignod lo moIl al spocific lom-
poraluros. Tlis mollod can bo usod as a simpIo and
oconomicaI vayof dolormining llal a minimumlompor-
aluro las boon acliovod, i.o., llo crayon moIls. Ono Iimi-
lalion is llal llo lomporaluro of llo compononl abovo
40
llo moIling lomporaluro of llo crayon is unInovn.
Wloro oxcossivo lomporaluro is a concorn, muIlipIo cray-
ons vill difforonl lomporaluros slouId bo ompIoyod.
Ior
proloal and voIding oporalions, inslanlanoous dovicos
sucl as conlacl pyromolors or dirocl-roading llormocou-
pIos vill anaIog or digilaI roadoul can bo usod. AII
dovicos slaII bo caIibralod or lavo somo moans of vori-
fying lloir abiIily lo moasuro llo dosirod lomporaluro
rango. Bocauso of lloir abiIily lo provido conlinuous
moniloring and dala slorago, llormocoupIos using clarl
rocordors or dala acquisilion sysloms slouId bo usod
ovor inslanlanoous moasuring dovicos for boll proloal
and IWHT oporalions.
5 XAMIhA1I0h
A surfaco oxaminalion slouId bo porformod lo
onsuro llal uso of a proloal aIlornalivo did nol rosuIl
in or promolo cracIing or ollor unaccoplabIo condilion.
VoIumolric oxaminalion of llo finaI voId, vloro
roquirod, slouId bo porformod in accordanco vill an
appIicabIo conslruclion or posl-conslruclion codo.
WoIds in ligl slrongll Iov aIIoy (HSIA) slooIs or
slooIs laving a CI abovo 0.5 aro prono lo doIayod
cracIing. A vailing poriod of 24 lr lo 48 lr lo dolocl
doIayod cracIing boforo finaI oxaminalion slouId bo
roquirod.
Tlo oxaminalion slouId bo documonlod and
incIudo, as a minimum: lypo of oxaminalion, vlal vas
oxaminod, vlo porformod llo oxaminalion, vlon il vas
porformod, and rosuIls of llo oxaminalion.
6 151IhC
Tosling slaII bo porformod in accordanco vill an
codo.
7 kFkhC5
ANSI/NB-23-2007, NalionaI Board Inspoclion Codo
IubIislor: Amorican NalionaI Sl andards Inslilulo
(ANSI), 25 Wosl 43rd Slrool, Nov YorI, NY 10036
AII 510-2006, Irossuro VossoI Inspoclion Codo:
Mainl onanco Inspoclion, Raling, Ropair, and
AIloralion
ASM HandbooI VoIumo 6: WoIding, Brazing, and
SoIdoring, Ninll Idilion
IubIislor: ASM InlornalionaI (ASM), 9639 Kinsman
Road, MaloriaIs IarI, OH 44073-0002
Codo Casos: N-373, N-594, N-606, N-638, N-644,
and 2321

Fig. 5 IIect eI weId ead Cress 5ectien en Cracking

ASMI B31.1-2007, Iovor Iiping
ASMI B31.3-2006, Irocoss Iiping
NY 10016-5990, Ordor Doparlmonl: 22 IavDrivo, I.O.
Box 2300, IairfioId, N} 07007-2300
AWS D1.1/D1.1M-2006, SlrucluraI WoIding Codo,
Appondix XI
IubIislor: Amorican WoIding Socioly (AWS), 550 NW
Io}ouno Road, Miami, II 33126
BIodgoll, O. W., Dosign of WoIdod Slrucluros, Tlo }amos
I. IincoIn Arc WoIding Ioundalion, CIovoIand, OH
41
Cary, H. B. , Modorn WoIding ToclnoIogy, Socond
Idilion, Ironlico HaII, Nov YorI, NY
Ilo, Y., and Bossyo, K., WoIdabiIily IormuIa of Higl
Slrongll SlooIs RoIalod lo Hoal Affoclod Zono
CracIing, , 1968
NovoII, }r., W. I., IurovoId Ild., Corlifiod MaloriaI Tosl
Roporls
NovoII, }r., W. I., Undorslanding and Using Carbon
IquivaIonl IormuIas, , Soplombor 1995
Sloul, R. D., WoIdabiIily of SlooIs, Iourll Idilion,
WoIding Rosoarcl CounciI, SlaIor Hoiglls, OH
(08)

ArticIe 2.9
AIternatives te PestweId heat 1reatment
1 5CkIP1I0h
Tlis ArlicIo addrossos aIlornalivos lo poslvoId loal
lroalmonl for ropair voIds. Undor corlain sorvico condi-
lions, IWHT of a ropair voId in accordanco vill llo
codo of conslruclion can bo inadvisabIo or impraclicaI.
An oxampIo of sucl a condilion vouId bo a ponolralion
or ombodmonl surroundod by roinforcod concrolo or
Iiquid modia llal couId bo damagod or croalo an unsafo
condilion by appIicalion of IWHT lomporaluros. In
addilion, inspoclion of prossuro vossoIs, lanIs, and pip-
ing vlicl lavo boon in sorvico can rovoaI dofocls or
damago vlicl roquiro voId ropair bul nol rodosign of
llo ilom conlaining llo dofocl. Tlo originaI conslruclion
codo or ovnor can roquiro poslvoId loal lroalmonl
(IWHT).
1.2 Facters AIIecting 5eIectien
IoslvoIdloal lroalmonl is appIiod lo forrilic voIds
and voIdod compononls lo roduco ligl IovoIs of rosiduaI
slross, provido lomporing lo roduco lardnoss, and lo
diffuso lydrogon.
Timo and lomporaluros for IWHT aro spocifiod
vill rospocl lo individuaI lypos of maloriaI and aro
soIoclod lo bo porformod boIov llo Iovor (crilicaI) lrans-
formalion lomporaluro of llo maloriaI.
AIlornalivos lo poslvoId loal lroalmonl can
invoIvo appIicalion of oIovalod proloal and/or impIo-
monlalion of spocific voIding loclniquos, boad soquonc-
ing, and incroasod conlroI of llo voIding procoss.
2 LIMI1A1I0h5
2.1 Pest-Censtructien Cede
2.2 Metheds
OnIy mollods llal aro rocognizod in an appIicabIo
codo of conslruclion or posl-conslruclion codo, quaIi-
fiod, or as juslifiod llrougl porformanco of a risI assoss-
monl ovaIualion, slaII bo usod.
2.2 5uitabiIity 1ests
Tosls lo domonslralo suilabiIily of llo ropair proco-
duro may bo noodod if sorvico condilions aro subjocl lo
42
lydrogon ombrillIomonl or al lomporaluros in llo croop
rango or if llo aIl ornalivo is boing considorod for
on-slroam ropairs or lol lapping on piping sysloms.
Tosling may bo in accordanco vill ovnor criloria, llo
2.3 kesistance te 5ervice Cenditiens
If rosislanco lo lydrogon or suIfido or slross cracIing
is a sorvico roquiromonl, losl ovidonco slaII bo dovoIopod
approprialo lo llo risI invoIvod lo slovllal a maximum
lardnoss in voId molaI and loal-affoclod baso molaI is
nol oxcoodod vlon quaIifying a spocific WoIding
Irocoduro Spocificalion (WIS). Maximum lardnoss
slaII bo as roquirod by llo ovnor, llo codo of conslruc-
lion, or posl-conslruclion codo.
2.4 kesiduaI 5tress keductien
If roduclion of rosiduaI slrossos in voIdmonls is
roquirod for succossfuI oporalion in sorvicos subjocl lo
slross corrosion cracIing (o.g., vloro aminos, causlics,
or carbonalos aro invoIvod), llon aIlornalivos lo posl-
voId loal lroalmonl slaII bo ovaIualod and dolorminod
lo bo accoplabIo for llo inlondod sorvico prior lo uso.
2.5 AItering MateriaI Preperties
Somo slooIs aro suscoplibIo lo molaIIurgicaI clango
sucl llal Ioss of nolcl louglnoss can occur in llo voId
loal-affoclod zono and in llo baso molaI. WoId molaI
can aIso oxporionco a Ioss of louglnoss and/or slrongll
vlon subjoclod lo IWHT. In ollor slooIs, inlorgranuIar
cracIing (oflon caIIod roloal or slross roIiof cracIing)
can occur in llo voId loal-affoclod zono during IWHT
vliIo oxcossivo poslvoId loal lroalmonl (lomporaluro
and loId limos) can aIso causo Ioss of slrongll in llo
voId and/or baso molaI.
3 5ICh
3.1 issimiIar MetaI weIds
WoIding invoIving dissimiIar maloriaIs slaII bo sopa-
raloIy ovaIualod unIoss spocificaIIy addrossod by llo
appIicabIo posl-conslruclion codo. Guidanco in llis aroa
is providod in Mollod 5, NBIC, of ANSI/NB-23.
3.2 Precedures
Roquiromonls for impIomonling aIlornalivos lo posl-
voId loal lroalmonl slouId bo oulIinod in spocific docu-
monlod inslruclions llal aro accompaniod by a quaIifiod
WoIding Irocoduro Spocificalion.

1abIe 1 5ummary eI PestweId heat 1reatment kequirements and PetentiaI AIternatives

APl 510 Paragraph 7.3.2
ASMF Sectlcn l Pw-39, Pw-/0
ASMF Sectlcn lll-h8]hC]hu]hF]hF]h6]hF Althcugh the Subsectlcns cf ASMF Sectlcn lll have rules fcr PwFT and alternatlves
(e.g., h8-/622), nuclear ccmpcnents and systems are unlque ln that they have
thelr cwn speclflc pcst-ccnstructlcn ccde fcr quallflcatlcn, repalr, and examlna-
tlcn, ASMF Sectlcn Xl (see belcw)
ASMF Sectlcn vlll, ulvlslcn 1 uCS-56, uFT-56, uFA-32, uFA-105, uhF-56, uCL-3/, uLw-26, uLT-56
ASMF Sectlcn vlll, ulvlslcn 2 AF-/02, AF-/20, AF-550, AF-630, AF-753, AF-75/, AF-820, AT-115,
Appendlx 26 (26-200)
ASMF Sectlcn vlll, ulvlslcn 3 KF-/00, KF-630, KF-830
ASMF Sectlcn lX w-290
ASMF Sectlcn Xl lwA-/600
ASMF 831.1 Paragraph 132.3, Tables 132 and 132.1
ASMF 831.3 Paragraph 331.2.2, Table 331.1.1
AwS u1.1 Paragraphs 5.8.2 and 5.8.3
AwS u10.8 Paragraph 6 and Table /
AwS u10.10 Paragraph 13.2
h8lC, h8-23 Part 3
4 FAkICA1I0h
4.1 AppIicatien eI Ievated Preheat
Many codos of conslruclion or posl-conslruclion
codos pormil uso of oIovalod proloal as an aIlornalivo
lo porforming poslvoId loal lroalmonl. IxampIos of
aIlornalivos can bo found in AII 510, ASMI BIVC
Socl ion I (IW-39), ASMI BIVC Soclion VIII,
ASMI B31.1 (TabIo 132), and ANSI/NB-23. Criloria aro
oxprossod as a funclion of baso molaI spocificalion, lypo,
grado, and llicInoss. TabIo 1 Iisls a varioly of IWHT
mollods and aIlornalos from polonliaI appIicabIo codos.
Tlo labIo is nol aII-incIusivo and slouId bo usod as a
guido for soIocling an aIlornalivo lo poslvoId loal lroal
for vorI llal is lo bo conduclod vill a spocific codo of
4.2 AIternative weIding Metheds
4.2.1 1emper ead weIding. Tomporing of voId
doposils may bo accompIislod by impIomonling spociaI
voId soquoncos and loclniquos. ConlroIIod doposilion
loclniquos sucl as lompor boad voIding, for oxampIo,
aro offorod in many conslruclion or posl-conslruclion
codos as an aIlornalivo lo poslvoId loal lroalmonl.
4.2.2 5atisIying Preperties. Tlo mollod usod slaII
produco voIdmonls llal salisfy moclanicaI and corro-
sion proporlios in accordanco vill llo appIicabIo codo
4.2.3 Absence eI Cede kuIes. Wlon no codo of
conslruclion or posl-conslruclion codo is spocifiod, llo
ruIos in AII 510, 7.2.3, ASMI BIVC Soclion IX, QW-290,
or ANSI/NB-23, Iarl 3, may bo usod as ruIos for con-
lroIIod doposilion voIding loclniquos.
43
4.3 kequiring AdditienaI Metheds
AppIicalion of aIlornalivo mollods may roquiro llal
roIiabIo proloal mainlonanco loclniquos, Iov lydrogon
voIding consumabIos, and oplimum maloriaIs slorago
praclicos bo impIomonlod.
5 XAMIhA1I0h
Ixaminalion slaII bo in accordanco vill llo appIica-
bIo codo of conslruclion or posl-conslruclion codo.
6 151IhC
Tosling slaII bo in accordanco vill llo appIicabIo codo
7 kFkhC5
AII 510, Irossuro VossoI Inspoclion Codo: Mainlonanco
Inspoclion, Raling, Ropair, and AIloralion, Rovision
06, 2006
Soclion I RuIos for Conslruclion of Iovor BoiIors
Soclion III, RuIos for Conslruclion of NucIoar IaciIily
Compononls, Subsoclions NCA, NB, NC, ND, NI, NI,
NG, and NH

Soclion VIII, RuIos for Conslruclion of Irossuro
VossoIs, Divisions 1, 2, and 3
Soclion IX, WoIding and Brazing QuaIificalions
Soclion XI, RuIos for Insorvico Inspoclion of NucIoar
Iovor IIanl Compononls
44
Box 2300, IairfioId, N} 07007-2300
AWS D1.1/D1.1M-2006, SlrucluraI WoIding Codo
SlooI
AWS D10.8-1996, Rocommondod Iraclicos for WoIding
Clromium-MoIybdonum SlooI Iiping and Tubing
AWS D10.10-1999, Rocommondod Iraclicos for IocaI
Hoaling of WoIds in Iiping and Tubing
Rocommondod Iraclicos for IocaI Hoaling of WoIds in
Irossuro VossoIs, WRC BuIIolin 452, }uno 2000.

ArticIe 2.10
In-5ervice weIding 0nte Carben 5teeI Pressure Cempenents
er PipeIines
1 5CkIP1I0h
Tlis ArlicIo addrossos llo roquiromonls and procau-
lions associalod vill voIding onlo prossuro compononls
or pipoIinos vliIo llo syslom is sliII in oporalion.
In-sorvico prossuro compononls or pipoIinos incIudo
prossuro oquipmonl and piping and aro dofinod as sys-
loms in vlicl llo conlonls may or may nol bo prossur-
izod and/or fIoving bul affocl llo vay llo voId cooIs.
Tlis ArlicIo is inlondod lo bo usod in conjunclion vill
Iarl 2 of llis documonl or anollor appIicabIo codo of
Tloro aro lvo primary concorns vlon porforming
in-sorvico voIding. Tlo firsl concorn is burn-llrougl,
aIso roforrod lo as bIovoul. A burn-llrougl occurs
vlon llo unmoIlod baso maloriaI undor llo voId pooI
Iosos llo abiIily lo conlain llo conlonls of llo prossuro
compononls or pipoIino aIIoving llo conlonls lo bo
oxpoIIod. WoIding onlo prossuro compononls or pipo-
Iinos vill llin vaIIs |o.g., 4.8 mm (0.188 in.) or Ioss] is
possibIo as Iong as procaulions aro laIon. Sucl procau-
lions incIudo conlroIIing llo loal inpul or ponolralion
of llo voIding procoss and using smaIIor diamolor oIoc-
lrodos |o.g., 2.4 mm (0.094 in.)] vlon llo vaII llicInoss
is Ioss llan 6.4 mm (0.250 in.). Safoly aspocls and conlin-
goncy pIanning aspocls for an occurronco of
burn-llrougl slouId bo pIannod for in accordanco vill
company praclicos, induslry sl andards (o. g., AII
Rocommondod Iraclico 2201), or posl-conslruclioncodo.
Tlo socond concorn is lydrogon cracIing. Hydrogon
cracIing occurs vlon lonsiIo slrossos aro acling on llo
voId, lydrogon is prosonl in llo voId and, vlon llo
voId soIidifios, llo rosuIlanl voId microslrucluro is
cracI suscoplibIo. If any of llo llroo condilions is oIimi-
nalod or roducod boIova llrosloId IovoI, llon lydrogon
cracIing viII nol occur. TonsiIo slrossos can aIvays bo
assumod duo lo llo slrinIago of llo voId upon cooIing.
Hydrogon, lypicaIIy, cannol bo oIiminalod bul can bo
roducod by using propor Iov lydrogon voIding pro-
cossos sucl as slioIdod molaI arc voIding vill IXX18
or IXX15 lypo oIoclrodos. CracI-suscoplibIo microslruc-
luros lypicaIIy lavo ligl microslrucluro lardnoss and
aro conlroIIod by llo carbon oquivaIonco of llo maloriaI
and llo ralo al vlicl llo voId cooIs.
Tlo IiIoIilood of dovoIoping microslrucluros suscop-
libIo lo lydrogoncracIing can bo liglbocauso in-sorvico
voIds lond lo lavo accoIoralod cooIing ralos duo lo llo
45
abiIily of llo prossuro compononls or pipoIino conlonls
lo puII loal from llo voId rogion. Tlo clanco of dovoI-
oping a cracI-suscoplibIo microslrucluro can bo roducod
by using voIding procoduros llal ovorcomo llo cooIing
offocl of llo prossuro compononls or pipoIino conlonls
or by aIloring llo prossuro compononls or pipoIino
oporaling condilions during in-sorvico voIding. Sucl
voIding procoduros incIudo using sufficionlIy ligl loal
inpul IovoIs or by using spocific voId doposi lion
soquoncos. Tlo mosl common in-sorvico voIding prac-
licos usod lo roduco lydrogon cracIing concorns incor-
poralo boll a Iov-lydrogon voIding procoss and a
voIding procoduro llal roducos llo suscoplibiIily of
forming a cracI-suscoplibIo microslrucluro. Tlo uso of
proloal is anollor loclniquo llal is commonIy usod lo
roduco llo suscoplibiIily of forming a cracI-suscoplibIo
microslrucluro bul il may bo difficuIl lo appIy lo
in-sorvico voIding appIicalions bocauso of llo abiIily of
llo prossuro compononls or pipoIino conlonls lo cooI
llo pipo vaII ospociaIIy for llin-vaIIod appIicalions. Tlo
cooIing offocl of llo prossuro compononls or pipoIino
conlonls can inlorforo vill aclioving llo propor pro-
loaling lomporaluro.
SuccossfuI appIicalion of in-sorvico voIding proco-
duros roquiros a baIanco bolvoon llo probabiIily of
burn-llrougl and roducing llo probabiIily of lydrogon
cracIing. Ior oxampIo, vlon voIding onlo a pipoIino
Ioss llan 6.4 mm (0.250 in.) llicI il migll bo nocossary
lo roduco llo voIding loal inpul lo Iovor llo probabiIily
of burn-llrougl, lovovor, llo Iovor voIding loal inpul
couId rosuIl in a voId microslrucluro vlicl is suscopli-
bIo lo lydrogon cracIing. Wlon llo maximum roquirod
voIding loal inpul lo oIiminalo llo probabiIily of
burn-llrougl is Iovor llan llo minimum roquirod loal
inpul lo prolocl againsl lydrogon cracIing llon aIlorna-
livo procaulions nood lo bo laIon (o.g., voIding proco-
duro vlicl incIudod a lompor boad doposilion
soquonco).
2 LIMI1A1I0h5
(08)

2.2 Piping and PipeIine MediIicatiens
Tlis ArlicIo is Iimilod lo appIicalion of in-sorvico
voIding. Tlougl llis ArlicIo covors in-sorvico voIding
aspocls, nol aII aspocls of prossuro compononls or pipo-
Iino modificalions llal aro porformod lo modify or
oxpand a piping syslom (o.g., llo lol-lapping procoduro
llal may foIIov llo in-sorvico voId) aro covorod by llis
ArlicIo. Tlis ArlicIo slouId bo usod in conjunclion vill
anollor appIicabIo codo of conslruclion or
posl-conslruclion codo vlicl doaIs vill llo spocifics of
llo prossuro compononls or pipoIino modificalion (o.g.,
for lol lapping, rofor lo AII Rocommondod Iraclico
2201).
2.3 Pressure Cempenents er PipeIine MateriaI
Tlis ArlicIo slaII bo Iimilod lo in-sorvico voIding onlo
aII carbon slooI prossuro compononls or pipoIinos. Tlis
ArlicIo oxcIudos voIding onlo slainIoss slooIs, aIIoyod
slooIs (o.g., Cr-Mo), or nonforrous maloriaIs.
2.4 Pressure Cempenents er PipeIine Centents
Boforo porforming any in-sorvico voIding, llo ovnor
slaII ovaIualo llo offocl llal in-sorvico voIding couId
lavo on llo conlonls of llo prossuro compononls or
pipoIino syslom (o.g., combuslion, oxpIosion, and
incroasod suscoplibiIily lo corrosion or ombrillIomonl).
In-sorvico voIding slouId onIy bo porformod on pros-
suro compononls or pipoIinos vloro llo ovaIualion indi-
calos llal lloro is nol a significanl risI associalod vill
polonliaI molaIIurgicaI dogradalion or clomicaI roaclion
from llo in-sorvico voIding procoss and nol a significanl
risI of clomicaI roaclion in llo procoss fIuid as a rosuIl
of polonliaI conlacl vill ligl molaI lomporaluros.
2.5 0perating Pressure
An adjuslmonl in llo prossuro during in-sorvico voId-
ing may nol bo roquirod from a voIding porspoclivo bul
may bo nocossary lo incroaso llo safoly of llo voIdor if
a burn-llrougl doos occur. Safoly aspocls and conlin-
goncy pIanning aspocls for an occurronco of a
burn-llrougl slouId bo pIannod for in accordanco vill
company praclicos, induslry sl andards (o. g., AII
Rocommondod Iraclico 2201), or posl-conslruclioncodo.
2.6 0perating FIew
An adjuslmonl in fIov during in-sorvico voIding may
incroaso lydrogon cracIing risI (o.g., incroaso fIov) or
burn-llrougl risI (o.g., roduco fIov). An adjuslmonl in
fIov slouId bo addrossod prior lo in-sorvico voIding.
2.7 PestweId heat 1reatment (Pwh1)
IWHT is difficuIl lo porform vliIo llo prossuro com-
pononls or pipoIino syslom romains in sorvico. If IWHT
is roquirod, llo ovnor slaII addross aII addilionaI con-
corns lo assuro llo voIding and subsoquonl IWHT viII
46
bo compIolodin a safo mannor. If llis cannol bo acliovod,
llon an aIlornalivo ropair mollod slaII bo ovaIualod.
3 5ICh
3.1 In-5ervice FiIIet weId Precedure
An in-sorvico fiIIol voId procoduro is dofinod as a
procoduro llal is usod lo join addilionaI maloriaI onlo
llo in-sorvico prossuro compononls or pipoIino lo roin-
forco a damagod aroa (o.g., fuII oncircIomonl sIoovos and
palcl pIalo ropairs) or lo faciIilalo a modificalion (o.g.,
propriolary fuII oncircIomonl lol-lap filling). Tlo fiIIol
voId slaII bo dosignod in accordanco vill an appIicabIo
3.2 In-5ervice Attachment weId Precedure
An in-sorvico allaclmonl voId procoduro is dofinod
as a procoduro llal is usod lo maIo a modificalion lo
oxisling prossuro compononls or pipoIino and usuaIIy
incIudos a groovo voId joinl. Tlo allaclmonl voId slaII
bo dosignod undor ono of llo foIIoving lvo criloria:
If llo allaclmonl providos adoqualo roinforcomonl
in accordanco vill an appIicabIo codo of conslruclion
or posl-conslruclion codo, no furllor roinforcomonl is
roquirod.
If llo allaclmonl doos nol provido adoqualo roin-
forcomonl in accordanco vill an appIicabIo codo of con-
slruclion or posl-conslruclion codo, addilionaI
roinforcomonl is roquirod.
3.3 In-5ervice weId MetaI uiIdup Precedure
Anin-sorvico voIdmolaI buiIdupprocoduro is dofinod
as a procoduro llal is usod lo doposil voId molaI onlo
llo surfaco of llo prossuro compononls or pipoIino lo
roinforco a llinnod aroa (o.g., molaI Ioss duo lo corrosion
or orosion). Tlo voId molaI buiIdup slaII bo dosignod
in accordanco vill an appIicabIo codo of conslruclion
4 FAkICA1I0h
4.1 weIding Precedure uaIiIicatien: weIding
Wlon approvod by llo voIding onginoor or voIding
inspoclor, a voIding procoduro quaIifiod lo llo appIica-
bIo nov conslruclion codo or posl-conslruclion codo
may bo usod for in-sorvico voIding appIicalions. Hov-
ovor, llo voIding procoduros llal aro lo bo usod for
voIding onlo in-sorvico prossuro compononls or pipoIino
slaII addross llo probabiIily of burn-llrougl and lydro-
gon cracIing. Wlon roquirod by llo voIding onginoor
or voIding inspoclor, llo voIding procoduro slaII bo
quaIifiod using llo sol-up oulIinod in Mandalory
Appondix I and llo losling in para. 4.2. Tlo ossonliaI
variabIos for llo voIding procoduro quaIificalion slaII
bo in accordanco vill an appIicabIo codo of conslruclion
or posl-conslruclion codo and slouId incIudo llo

in-sorvico voIding ossonliaI variabIos Iislod in
para. 4.1.1.

4.1.1 In-5ervice weIding ssentiaI variabIes. Tlo
in-sorvico voIding ossonliaI variabIos aro spocific
roquiromonls for in-sorvico voIding llal slouId bo usod
in addilion lo llo ossonliaI variabIos from an appIicabIo
4.1.1.1 weId 1ype. In-sorvico voIds slaII bo
groupod inlo ono of llo foIIoving llroo lypos and quaIi-
fiod soparaloIy:
in-sorvico fiIIol voId
in-sorvico allaclmonl voId
in-sorvico voId molaI buiIdup
4.1.1.2 CeeIingPetentiaI. Tlo ralo al vlicl a voId
cooIs, or cooIing polonliaI, is an ossonliaI variabIo |o.g.,
cooIing limo from 800C lo 500C (1472I lo 932I) (soc)
or cooIing ralo al 556C (1,000I) (/soc)]. An incroaso
in llo cooIing polonliaI of llo in-sorvico prossuro compo-
nonl or pipoIino groalor llan llo cooIing polonliaI usod
during llo quaIificalion of llo voIding procoduro
roquiros roquaIificalion. Tlo cooIing polonliaI may bo
dolorminod by dirocl moasuromonl, caIcuIalion, com-
pulor modoIs, or a combinalion of lloso mollods.
NOTI: In llo procoduro quaIificalion, vaII llicInoss is nol an
ossonliaI variabIo bul is diroclIy roIalod lo llo cooIing polonliaI of
llo prossuro compononls or pipoIino, vlicl is an ossonliaI variabIo.
4.1.1.3 Carben quivaIence. Tlo in-sorvico voId-
ing procoduro slouId bo groupod according lo carbon
oquivaIonco of llo maloriaI. Carbon oquivaIonco is spoci-
fiod soparaloIy for llo in-sorvico prossuro compononls
or pipoIino and llo socond baso maloriaI (o.g.,
fuII-oncircIomonl sIoovo or allaclmonl maloriaI). An
in-sorvico voIding procoduro quaIifiod on a spocific car-
bon oquivaIonl maloriaI may aIso bo adoqualo for Iovor
carbon oquivaIonl maloriaIs assuming llo cooIing polon-
liaIs aro llo samo. Aprocoduro quaIifiod on Iovor carbon
oquivaIonl maloriaI can bo usod in a ropair appIicalion
on a liglor carbon oquivaIonl maloriaI providod llal
llo cooIing polonliaI of llo ropair appIicalion is Ioss llan
llo cooIingpolonliaI of llo quaIifiod procoduro and lloro
is no incroaso in lydrogon cracIing suscoplibiIily. Tlo
carbon oquivaIonl slouId bo caIcuIalod using llo foIIov-
ing formuIa vill llo oIomonls oxprossod in voigll por-
conl amounls:
CI C +
Mn
6
+
Cr + Mo + V
5
+
Ni + Cu
15
4.1.1.4 weIding Precess. A clango in llo voIding
procoss slaII roquiro roquaIificalion.
47
4.1.1.5 weIding CensumabIe. An incroaso in llo
diffusibIo lydrogon IovoI of llo voIding consumabIo or
a clango in llo oIoclrodo lypo as dofinod by
TabIo QW-432 in ASMI BIV Codo Soclion IX, or anollor
codo, slaII roquiro roquaIificalion.
4.1.1.6 heat Input. Tlo loal inpul rango is dolor-
minod by llo voId procoduro quaIificalion and is llo
rango llal viII produco a voId llal viII nol burn llrougl
and las a Iov IiIoIilood of producing a cracI-
suscoplibIo microslrucluro. A clango in llo loal inpul
rango slaII roquiro roquaIificalion. Tlo loal inpul
slouId bo caIcuIalod in accordanco vill QW-409.1(a) or
(b) in ASMI BIV Codo Soclion IX, or anollor appIicabIo
An incroaso in llo loal inpul ovor llo rango spoci-
fiod in llo in-sorvico procoduro quaIificalion or spocifiod
in llo in-sorvico voIding procoduro slaII bo ovaIualod
for burn-llrougl risI. Tlo probabiIily of burn-llrougl
slouId bo ovaIualod oxporimonlaIIy, by compulor simu-
Ialion, or a combinalion of lloso mollods.
Adocroaso in llo loal inpul boIovllo rango spoci-
fiod in llo in-sorvico procoduro quaIificalion or spocifiod
in llo in-sorvico voIding procoduro slaII roquiro roquaIi-
ficalion lo dolormino llo probabiIily of lydrogon cracI-
ing suscoplibiIily. Hydrogon cracIing suscoplibiIily
slouId bo ovaIualod using llo losl oulIinod in para. 4.2.
4.1.1.7 weIding Current. A clango in llo rango of
voIding curronl usod in llo procoduro quaIificalion or
spocifiod in llo voIding procoduro slaII roquiro
roquaIificalion.
4.1.1.8 PestweId akeeut. A roduclion of llo lom-
poraluro or limo of llo appIicalion of a poslvoIdbaIooul
slaII roquiro roquaIificalion. Wlon spocifiod, llo mini-
mum soaIing lomporaluro and limo slaII bo spocifiod.
Any polonliaI offocl llo poslvoId baIooul las on llo
prossuro compononls or pipoIino conlonls slaII bo
ovaIualod.
4.1.1.9 Preheat. A roduclion of llo lomporaluro
or limo of appIicalion of a proloal roquiromonl slaII
roquiro roquaIificalion. Wlon spocifiod, llo minimum
soaIing lomporaluro and limo slaII bo spocifiod. Any
polonliaI offocl llo proloal roquiromonl las on llo pros-
suro compononls or pipoIino conlonls slaII bo ovaIualod.
4.1.1.10 hydregen akeeut. A clango in llo lom-
poraluro or limo of appIicalion of llo lydrogon baIooul
procoduro slaII roquiro roquaIificalion. Any polonliaI
offocl llo lydrogon baIooul roquiromonl las on llo pros-
suro compononls or pipoIino conlonls slaII bo ovaIualod.
4.1.1.11 5urIace ead PIacement. Any clango in
voId boad posilion or doposil ion soquonco of llo
in-sorvico voIding procoduro slaII roquiro
roquaIificalion.

1abIe 1 1ype and humber eI 1est 5pecimens kequired Ier an In-5ervice
weIding Precedure uaIiIicatien

12.7 mm Flllet / . . . / 2 2
(0.500 ln.) Attachment / . . . / 2 2
weld metal bulldup / . . . . . . 2 2
12.7 mm Flllet / . . . / 2 2
(0.500 ln.) Attachment / . . . / 2 2
weld metal bulldup 2 2 . . . 2 2
4.2 weId Precedure uaIiIicatien: 1esting
WoIding procoduros llal aro lo bo usod lo voId onlo
in-sorvico prossuro compononls or pipoIinos slaII
addross llo probabiIily of burn-llrougl and lydrogon
cracIing suscoplibiIily. Tlo probabiIily of burn-llrougl
slouId bo ovaIualod oxporimonlaIIy, by compulor simu-
Ialion, or a combinalion of lloso mollods. Hydrogon
cracIing suscoplibiIily slouId bo ovaIualod by doslruc-
livo and nondoslruclivo losling. Wlon approvod by llo
voIding onginoor or voIding inspoclor, a voIding proco-
duro quaIifiod lo llo appIicabIo nov conslruclion codo
or posl-conslruclion codo may bo usod for in-sorvico
voIding appIicalions. Wlon roquirod by llo voIding
onginoor or voIding inspoclor, llo voIding procoduro
slaII bo quaIifiod usingllo sol-up oulIinod inMandalory
Appondix I and losling in para. 4.2. Tlo ossonliaI vari-
abIos for llo voIding procoduro quaIificalion slaII bo in
accordanco vill an appIicabIo codo of conslruclion or
posl-conslruclion codo and slouIdincIudo llo in-sorvico
voIding ossonliaI variabIos Iislod in para. 4.1.1.
4.2.1 estructive 1est Metheds. In-sorvico voIding
procoduro losl sampIos slaII bo laIon fromllo procoduro
quaIificalion voId coupon as spocifiod in para. 4.2.2. Tlo
procoduro slaII bo quaIifiod by succossfuI compIolion of
llo losls spocifiod in paras. 4.2.1.1 llrougl 4.2.1.4. Tlo
numbor of losls for oacl in-sorvico voIding procoduro
is givon in TabIo 1. Tvo procoduro quaIificalion voId
coupons slouId bo fabricalod if lloro is nol onougl
maloriaI avaiIabIo for aII of llo losl sampIos in ono proco-
duro quaIificalion. Tlo doslruclivo losl spocimons slaII
bo maclinod in accordanco vill AWS B4.0 or ollor
appIicabIo slandard.
4.2.1.1 Macre-5ectien 1est. Tlo macro-soclionlosl
sampIos slaII bo romovod and maclinod using nonllor-
maI mollods. Tlo macro-soclion losl sampIo slouId bo
in accordanco vill ASTM I 3 or anollor oquivaIonl
documonl lo givo a cIoar roprosonlalion of llo voId
rogion. VisuaI oxaminalion of llo macro-soclion losl
sampIos slaII slov
compIolo fusion
no cracIs
48
no undorcul oxcooding 0.8 mm (0.031 in.) or 10
of llo simuIalod in-sorvico prossuro compononls or pipo-
Iino vaII llicInoss, vliclovor is smaIIor
Ior fiIIol voIding procoduros onIy, llo fiIIol voId
Iog Ionglls aro al Ioasl oquaI lo llo Iog Iongll spocifiod
in llo voIding procoduro or ollor appIicabIo procoss
conlroI documonl.
4.2.1.2 hardness 1est. Tlo lardnoss losl sampIos
slaII bo loslod in accordanco vill ASTM I 384 or
anollor oquivaIonl documonl. A minimum of fivo
VicIors lardnoss indonls, using a 10-Ig Ioad, slaII bo
mado in llo coarso-grainod loal affoclod zono of llo
voId loo in accordanco vill Iig. 1. Tlo macro-soclion
losl sampIos may bo usod for llo lardnoss losl sampIos
aflor llo molaIIograplic anaIysis las boon compIolod.
4.2.1.3 hick-reak 1est. NicI-broaI losl sampIos
slaII bo romovod and maclinod using nonllormaI moll-
ods, and slaII bo loslod according lo AWS B4.0 or
anollor oquivaIonl documonl. VisuaI inspoclion of llo
nicI-broaI losl sampIo fracluro surfacos slaII slov
compIolo fusion
no singIo poro oxcoods 1.6 mm (0.063 in.) in sizo,
and llo combinod aroa of aII poros doos nol oxcood 2
of llo oxposod fracluro surfaco aroa
no sIag incIusion oxcoods 0.8 mm (0.031 in.) in
dopll and 3.2 mm (0.125 in.) or ono-laIf llo nominaI
pipo vaII llicInoss in Iongll, vliclovor ono is smaIIor.
Tlo dislanco bolvoon adjaconl sIag incIusions slaII nol
bo Ioss llan 12.7 mm (0.500 in.).
fisloyos, as dofinod in AWS A3.0, slouId nol bo
causo for rojoclion
4.2.1.4 Face er 5ide end 1est. Tlo bond losl sam-
pIos slaII bo maclinod using nonllormaI mollods, and
slaII bo loslod according lo AWS B4.0 or anollor oquiva-
Ionl documonl.
1
Tlo bond losl sampIos slouId bo bonl
in a guidod-bond losl jig or oquivaIonl oquipmonl. Ior
1
Tlo simuIalod in-sorvico prossuro compononls or pipoIino nicI-
broaI losl sampIo for a fiIIol or allaclmonl voIding procoduro can
bo usod for llo faco bond losl sampIo.

Fig. 1 heat-AIIected Zene hardness Indent Lecatiens
6FhFkAL hUTFS:
(a) lndents are spaced 0.2 mm (0.008 ln.) frcm fuslcn llne and 0.6 mm (0.02/ ln.) apart. lnltlal lndent ls lccated 0.6 mm (0.02/ ln.) frcm
weld tce.
(b) The flgure ls nct tc scale.
49

Fig. 2 MandreI Lecatien keIative te the weId 1ee when eing Face end 1est Ier a 1ypicaI In-5ervice FiIIet
weId

6FhFkAL hUTFS:
(a) The dashed pcrtlcn cf the ccmpleted weld needs tc be remcved prlcr tc testlng.
faco bonds, llo bond losl sampIo slaII bo pIacod vill
llo faco of llo voId opposilo llo mandroI (Iig. 2). Tlo
voIdroinforcomonl slouId bo romovod prior lo bonding.
Tlo romaining voId slouId nol oxcood 1.6 mm
(0.063 in.). Tlo bond losl sampIo slaII bo bonl unliI llo
curvaluro of llo bond losl spocimon is approximaloIy
a U-slapo (Iig. 3). VisuaI inspoclion of llo bond losl
spocimons slaII slov
no cracIs or ollor voId fIavs oxcooding 3.2 mm
(0.125 in.) or ono-laIf llo nominaI pipo vaII llicInoss,
vliclovor is smaIIor, in Iongll aro prosonl in llo voId
or fusion zono
cracIs llal originalo from llo odgo of llo bond
losl spocimon llal aro Ioss llan 6.4 mm (0.250 in.) in
Iongll in any diroclion slouId nol bo causo for rojoclion
unIoss an obvious voId fIav is prosonl
4.2.2 5ampIe Lecatien. Tlo Iocalions of llo
in-sorvico voIding procoduro losl sampIos for a fiIIol
voId slouId bo laIon from oquaIIy spacod inlorvaIs
around llo procoduro quaIificalion voId coupon as
slovn in Iig. 4. Tlo Iocalions of llo in-sorvico voIding
procoduro losl sampIos for an allaclmonl voIdslouIdbo
laIon from oquaI spacod inlorvaIs around llo procoduro
quaIificalion voId coupon vill sampIos laIon fromboll
llo crolcl and saddIo porlions of llo voId as slovn in
Iig. 5. Tlo Iocalions of llo in-sorvico voIding procoduro
losl sampIos for a voId buiIdup voId coupon slouId bo
laIon as slovn in Iig. 6.
4.3 weIder PerIermance uaIiIicatien
WoIdors llal aro lo porform in-sorvico voIding onlo
prossuro compononls or pipoIinos slaII domonslralo llo
abiIily lo doposil voIds llal produco microslrucluros
llal aro cracI suscoplibIo and/or avoid burning
llrougl llo prossuro compononl or pipoIino. Tlis may
bo domonslral od by succossfuIIy doposiling an
50
in-sorvico voId or by quaIifying a voIdor using llo sol-
up dolaiIod in Mandalory Appondix I and losling
roquiromonls oulIinod in para. 4.2.
5 XAMIhA1I0h
5.1 h Methed
Tlo in-sorvico voId, mado in llo fioId, slaII bo oxam-
inod aflor voIding las boon compIolod. Tlo mollod of
oxaminalion slaII bo in accordanco vill an appIicabIo
codo of conslruclion or posl-conslruclion codo vill llo
addilionaI abiIily lo Iocalo voId fIavs incIuding lydro-
gon cracIing sinco il is a major concorn for in-sorvico
voIding undor llo sorvico condilions (o.g., oporaling
lomporaluro). Tlo accoplanco criloria for llo NDI oxam-
inalion slaII bo in accordanco vill an appIicabIo codo
of conslruclion or posl-conslruclion codo. If voIding
vas dono lo ropair a sorvico inducod dofocl, llo NDI
mollod llal vas usod lo dolocl llo dofocl slaII bo usod
lo vorify romovaI of llo dofocl.
Wlon NDI procoduros aro appIiod aflor in-sorvico
voIding, spociaI procoduros may bo nocossary vloro llo
compononls aro oporaling al lomporaluros significanlIy
abovo ambionl.
5.2 xaminatien 1ime
Wlon lydrogon cracIing is a concorn, in-sorvico
voIds slouId bo oxaminod 24 lr lo 72 lr aflor voIding
las boon compIolod.
6 151IhC
Tosling slouId bo compIolod in accordanco vill an
codo. If lydro-losling of a lol-lapping compononl aflor

Fig. 3 xampIes eI In-5ervice weIding Precedure uaIiIicatien Face end 1est 5ampIes
Fig. 4 1est 5ampIe Lecatiens Ier In-5ervice FiIIet weIding Precedure uaIiIicatien Assuming quaI 5pacing
Areund the CircumIerence te 0btain AII the kequired 1est 5pecimens

6FhFkAL hUTFS:
(a) h8 nlck-break test sample, F8 face bend test sample, MS metallcgraphlc test sample
(b) hct tc scale.
51

Fig. 5 1est 5ampIe Lecatiens Ier In-5ervice Attachment weIding Precedure uaIiIicatien Assuming quaI
5pacing Areund the CircumIerence te 0btain AII the kequired 1est 5pecimens
6FhFkAL hUTFS:
(a) h8 nlck-break test sample, F8 face bend test sample, MS metallcgraphlc test sample
(b) hct tc scale.
inslaIIalion is conlompIalod, llo usor is advisod lo con-
sidor llo lomporaluro of llo oporaling compononl in
ordor lo avoid laving llo losl fIuid fIasl lo sloam.
7 kFkhC5
AGA IipoIino Ropair ManuaI, Docombor 31, 1994
IubIislor: Amorican Gas Associalion (AGA), 400 Norll
CapiloI Slrool NW, Suilo 450, Waslinglon, DC 20001
AII Rocommondod Iraclico 2201, Safo Hol Tapping
Iraclicos in llo IolroIoum & IolroclomicaI Induslrios
AII Rocommondod Iraclico 579-1
AII/ASMI IIS-1, Iilnoss-Ior-Sorvico
AII Slandard 1104, WoIding of IipoIinos and RoIalod
IaciIilios
ANSI/AWS A3.0, Slandard Dofinilions, IncIuding
Torms for Adlosivo Bonding, Brazing, SoIdoring,
TlormaI Culling, and TlormaI Spraying
ANSI/AWS B4.0, Slandard Mollods for MoclanicaI
Tosling WoIds
IubIislor: Amorican NalionaI Slandards Insil iluo
52
ASMI B31.1, Irossuro Iiping
ASMI B31.4, IipoIino Transporlalion Sysloms for Iiquid
Hydrocarbons and Ollor Iiquids
ASMI B31.8, Gas Transmission and Dislribulion Iiping
Sysloms
Soclion IX, WoIding and Brazing QuaIificalions,
ArlicIo II WoIding Irocoduro QuaIificalions: ArlicIo
III WoIding Iorformanco QuaIificalions
Box 2300, IairfioId, N} 07007-2300
ASTM I 3, Slandard Iraclico for Iroparalion of
MolaIIograplic Spocimons
ASTM I 384, Slandard Tosl Mollod for
Microindonlalion Hardnoss of MaloriaIs
IubIislor: ASTM InlornalionaI (ASTM), 100 Barr Harbor
Road, I.O. Box C700, Wosl ConslolocIon, IA
19428-2959
CSA Slandard Z662, OiI and Gas IipoIino Sysloms
IubIislor: Canadian Slandards Associalion (CSA), 5060
Spoclrum Way, Mississauga, Onlario I4W 5N6,
Canada

Fig. 6 1est 5ampIe Lecatiens Ier In-5ervice weId MetaI uiIdup weIding Precedure uaIiIicatien
6FhFkAL hUTFS:
(a) S8 slde bend test sample, F8 face bend test sample, MS metallcgraphlc test sample.
53

ArticIe 2.10, Mandatery Appendix I
In-5ervice weIding Precedure]weIder PerIermance
uaIiIicatien 5etup
Tlo inlonl of producing a simuIalod in-sorvico voId-
ing procoduro quaIificalion is lo maIo voIds llal viII
bo moro IiIoIy lo produco lydrogon cracIing during
llo quaIificalion llan in llo fioId. Tlis can bo dono by
maIing voIds on liglor carbon oquivaIonl carbon slooI,
by using a liglor cooIing polonliaI, or by incorporaling
boll variabIos lo lavo a moro consorvalivoIy quaIifiod
procoduro.
Tlo simuIalod in-sorvico solup usod for llo in-sorvico
procoduro quaIificalion can bo any appIicabIo joinl con-
figuralion, bul il is imporalivo llal llo in-sorvico proco-
duro quaIificalion voId coupon bo moro suscoplibIo lo
lydrogon cracIing. Il is good praclico lo simuIalo llo
acluaI fioId voId llal viII bo mado using llo in-sorvico
voIding procoduro. Il is common for llo in-sorvico pro-
duclion quaIificalion voId lo bo mado using a liglor
carbon oquivaIonl carbon slooI pipo vill valor bacIing
bocauso valor las boon slovn lo cooI voIds faslor llan
any ollor cooIing modium. Il is imporlanl lo nolo llal
using valor as llo cooIing modium may maIo llo voId-
ing procoduro ovorIy consorvalivo lo llo poinl of maIing
il impossibIo lo succossfuIIy quaIify llo voId coupon.
Tlo in-sorvico procoduro quaIificalion coupon slouId
lavo sufficionl Iongll lo romovo aII of llo roquirod losl
spocimons. Moro llan ono assombIy may bo usod if aII
llo roquirod spocimons cannol bo romovod from a singIo
assombIy. Tlo cooIing modium slouId bo circuIalod
llrougl llo losl assombIy prior lo voIding. Tlo simu-
Ialod in-sorvico solup slouId bo proparod as foIIovs:
54
Tlo simuIalod in-sorvico solup for an in-sorvico
fiIIol voId slouId bo proparod in a mannor simiIar lo
Iig. I-1 or an aIlornalivo posilion llal vouId simuIalo
llo in-sorvico voIding appIicalion. Tlo sIoovo slouId
lavo a cIoso fil lo llo carrior pipo unIoss a spociaI dosign
sIoovo filling is lo bo quaIifiod. Tlo sIoovo IongiludinaI
groovo voIds slouId bo voIdod prior lo llo in-sorvico
fiIIol voIds lo improvo fil-up |soo Nolo lo Iig. I-1].
allaclmonl voId slouId bo proparod in a mannor simiIar
lo Iig. I-2 or an aIlornalivo posilion llal vouId simuIalo
llo in-sorvico voIding appIicalion. Tlo lacI voIds
slouId bo ground lo assuro compIolo fusion aIong llo
onliro Iongll of llo voId. No losl sampIos slaII bo laIon
from llo lacI Iocalions.
voId molaI buiIdup voId slouId bo proparod in a man-
nor simiIar lo Iig. I-1 bul villoul using llo sIoovo. Tlo
voId viII bo doposilod diroclIy onlo llo pipo vaII. Il is
common lo moclanicaIIy romovo a spocifiod amounl
of vaII lo simuIalo corrosion Ioss. Tlo probabiIily of
burn-llrougl slaII bo ovaIualod boforo voId molaI
buiIdup is porformod using llo quaIifiod procoduro in
llo fioId.
Aflor compIolion of llo procoduro quaIificalion voId,
llo cooIing modium slaII conlinuo unliI llo onliro
assombIy las acliovod a uniform oquiIibrium
lomporaluro.

Fig. I-1 Precedure and weIder uaIiIicatien 1est AssembIy Ier an In-5ervice FiIIet weId
6FhFkAL hUTF: The lcngltudlnal weld seam ls nct ccnsldered an ln-servlce weld unless the lcngltudlnal seam weld fuses tc the slmulated
ln-servlce plpe.
55

Fig. I-2 Precedure and weIder uaIiIicatien 1est AssembIy Ier an In-5ervice Attachment weId
56

ArticIe 2.11
weId uiIdup, weId 0verIay, and CIad kesteratien
1 5CkIP1I0h
1.1 Intreductien
Tlis ArlicIo addrossos llo ropair and rosloralion by
voId buiIdup or voId ovorIay of carbon slooI baso molaI,
Iov aIIoy slooI baso molaI, and corrosion rosislanl cIad-
ding or voId ovorIay on inlornaI surfacos of prossuro
vossoIs and piping llal lavo oxporioncod vaII llinning.
1.2 5cepe
Ropairs lo voId ovorIay or cIadding can invoIvo
ropIacomonl of llo onliro llicInoss of llo cIadding or
voId ovorIay, or a parliaI llicInoss of llo voId ovorIay.
1.3 amaged ase MetaI
In carbon slooI or Iov aIIoy slooI appIicalions, voId
ovorIay or voId buiIdup can bo usod lo robuiId aroas llal
aro vorn from orosion, corrosion, or fIov-accoIoralod
corrosion (IAC), or vlicl lavo boon ground oul lo
romovo dofocls sucl as cracIs. Tlo originaI prossuro
boundary inlogrily of llo baso molaI can bo roslorod.
1.4 amaged weId 0verIay and CIadding
Corrosion rosislanl voId ovorIay can bo usod lo
ropIaco damagod aroas llal originaIIy lad simiIar ovor-
Iay, or llal originaIIy lad corrosion rosislanl cIadding
ovor carbon slooI or Iov aIIoy slooI maloriaI. Corrosion
rosislanl voId ovorIay can aIso bo usod lo bacI-cIad
soams llal lavo boon ropairod on cIad maloriaI vill
carbon slooI or Iov aIIoy slooI baso molaI.
1.5 eIinitiens
1.5.1 weId 0verIay. Ior llo purposo of llis ArlicIo,
voId ovorIay rofors lo llo appIicalion of corrosion rosis-
lanl voId molaI on carbon slooI or Iov aIIoy baso molaI.
1.5.2 weId uiIdup. WoId buiIdup rofors spocificaIIy
lo llo appIicalion of carbon slooI or Iov aIIoy voId
molaI, appIiod for llo purposo of rosloring baso molaI
llicInoss.
1.5.3 CIad kesteratien. CIad rosloralion rofors lo
llo appIicalion of corrosion rosislanl voId molaI on car-
bon slooI or Iov aIIoy baso molaI, for llo purposo of
rosloring llo originaI corrosion rosislanl voId ovorIay
or cIadding. Tlo originaI cIadding couId lavo boon
appIiod by mollods sucl as roII bonding or oxpIosion
bonding.
57
1.5.4 ack CIadding. BacI cIadding rofors lo llo
appIicalion of corrosion rosislanl voId molaI on a carbon
slooI or Iov aIIoy slooI voId in cIad maloriaI vlicl las
boon ropairod.
1.5.5 IIective epth. Tlo dopll boIov llo finislod
voId surfaco al vlicl voId molaI clomicaI anaIysis is
porformod. Ior llo purposo of llis ArlicIo, llo offoclivo
dopll is as dofinod in ASMI BIVC Soclion IX,
QW-462.5(a).
2 LIMI1A1I0h5
2.2 ase MetaI Cenditien
Tlis ArlicIo slaII appIy lo vaII llinning and doos nol
spocificaIIy addross ollor lypos of surfaco dofocls. Soo
ArlicIo 3.4, IIavIxcavalion and WoId Ropair for ollor
lypos of surfaco dofocls. Tlo romaining baso molaI llicI-
noss slaII bo adoqualo lo accommodalo voId buiIdup.
3 5ICh
3.1 Cause eI amage
Irior lo ropair voIding, dolorminalion slouId bo
mado of llo causos of llo damago lo llo voId ovorIay,
cIadding, or baso molaI. Tlo uso of voId ovorIay or voId
buiIdup as a pormanonl ropair slouId incIudo considor-
alion of llo llinning moclanism and ils provonlion.
Considoralion slouId bo givon lo ropIacomonl of aII or
parl of llo voId ovorIay in caso lloro is damago lo llo
cIadding or voId ovorIay (corrosion, ombrillIomonl and
cracIing, olc.).
3.2 humber eI weId Layers
WoId ovorIay or bacI cIadding may bo doposilod in
ono or moro Iayors. Moro llan ono Iayor is roquirod
vloro lompor-boad loclniquos aro usod. Tlo numbor
of voId Iayors in produclion slaII nol bo Ioss llan llo
numbor of Iayors doposilod for voId ovorIay procoduro
quaIificalion losls.
3.3 weId 1hickness
Tlo lolaI dopll of ovorIay or bacI cIadding slaII
bo 3 mm (
1
8
in.) or groalor in llicInoss, unIoss ollorviso
(08)

spocifiod. In aII casos, llo voId ovorIay llicInoss and llo
baso molaI llicInoss slaII al Ioasl oquaI llo minimum
llicInoss of llo undamagod molaI.
3.4 MuItipIe-Layer weIding
If muIlipIo-Iayor ovorIay or bacI cIadding is roquirod
lo mool llo spocifiod clomislry, and subsoquonl maclin-
ing or grinding is nocossary lo salisfy dimonsionaI
roquiromonls, llo finaI maclinod or ground ovorIay
llicInoss slaII nol bo Ioss llan llo quaIifiod llicInoss.
IxampIos incIudo maclining of gasIol groovos in
fIangos and luboslools or grinding of loal oxclangor
sloII insido diamolor lo pormil insorlion of lubo bundIo.
3.5 ase MetaI kesteratien
Wlon llo slrongll of llo originaI baso molaI is lo bo
roslorod by voId buiIdup, llo voId molaI lonsiIo
slrongll slouId oquaI or oxcood llal of llo baso molaI.
Considoralion slouId aIso bo givon lo compalibiIily of
llo voId molaI vill llo baso molaI and suilabiIily for
llo inlondod sorvico.
3.6 Cerresien Pretectien
Wloro voId ovorIay is appIiod for corrosion proloc-
lion, sucl as slainIoss slooI ovorIay on carbon slooI or
Iov aIIoy baso molaI, approprialo voId clomislry (sucl
as Typo 309 foIIovod by Typo 308 fiIIor molaI) slouId
bo spocifiod.
3.7 esign CaIcuIatiens
AII dosign caIcuIalions slouId bo in accordanco vill
llo originaI codo of conslruclion. If ovorIay or cIadding
is incIudod in llo llicInoss caIcuIalions, llo caIcuIalions
slaII bo in accordanco vill llo originaI codo of conslruc-
lion or, vlon nono oxisls, lloy may bo basod on ASMI
BIVC Soclion VIII, Division 1, UCI-23.
3.8 0ther Censideratiens
3.8.1 iIIerentiaI 1hermaI xpansien. Considor-
alion slouId bo givon lo difforonliaI llormaI oxpansion
bolvoon llo baso molaI and voId ovorIay.
3.8.2 CaIvanic Cerresien. Tlo possibiIily of gaIvanic
corrosion slouId bo considorod in llo baso molaI al llo
odgo of ligl aIIoy or nonforrous voId ovorIay.
4 FAkICA1I0h
4.1 5urIace Preparatien
Surfacos lo bo voIdod slaII bo froo of rusl, scaIo, painl,
coalings, and ollor conlaminanls, and slaII lavo a
smooll conlour. If surfacos aro lo bo proparod by bIasl-
ing, modia slouId bo froo of siIica llal vouId inlorforo
vill subsoquonl voIding oporalions.
58
4.2 weIding Precedure uaIiIicatien
WoIding procoduros, voIdors, and voIding oporalors
slaII bo quaIifiod in accordanco vill llo curronl roquiro-
monls of llo appIicabIo codo of conslruclion or
BIVC Soclion IX may bo usod for procoduro and por-
formanco quaIificalions. TypicaIIy, somiaulomalic voId-
ing procossos sucl as GMAW aro usod lo maximizo
produclivily andlo minimizo loal inpul. Ior Iargor aroas
lo bo voIdod, maclino approaclos using voIding oquip-
monl mounlod on lracIs for bollor conlroI and produc-
livily ralos may bo approprialo.
4.3 weId 0verIay
4.3.1 heat Input. AppIicalion of llo firsl ovorIay
pass in llin sloIIs slaII bo sucl llal ponolralion, and
llus llo polonliaI for burn-llrougl, is minimizod. In
gonoraI, loal inpul slaII bo minimizod lo provonl burn-
llrougl and dislorlion.
4.3.2 weId 0verIay 1hickness. WoId ovorIay llicI-
noss slaII bo vorifiod by acluaI moasuromonl of llo
oxposod odgo al voId joinl proparalions or ropair cavi-
lios. Quoslions rogarding ovorIay llicInoss slouId bo
rosoIvod by llicInoss moasuromonls. ConsuIlalion vill
an NDI spociaIisl may bo nocossary.
4.4 ack CIadding
4.4.1 weId Creeve Preparatien. (TypicaI voId joinl
dolaiIs for bacI cIadding aro slovn in Iig. 1.)
Irior lo bacI cIadding bull joinls, llo voId groovo in
llo bacIing maloriaI slaII bo fiIIod approximaloIy fIusl
vill, bul nol moro llan 1.5 mm (
1
16
in.) boIov llo voId
ovorIay fusion Iino or llo cIad bond Iino adjaconl lo llo
voId groovo prior lo bacI cIadding. Caro slaII bo laIon
lo avoid cross-conlaminaling llo cIadding and bacIing
maloriaI voId molaI. Any suspoclod aroas of cross-
conlaminalion slaII bo olclod vill oillor a nilric acid
or coppor suIfalo soIulion lo confirm llo Iocalion of llo
cIad/subslralo inlorfaco.
4.4.2 5trip ack. Irior lo bacI cIadding bull joinls,
cIadding slaII bo slrippod bacI a minimum of 6 mm
(
1
4
in.) from llo odgo of llo pIalo, pipo, or filling.
4.5 5peciaI Censideratiens Ier Lew AIIey 5teeIs
4.5.1 ehydregenatien heat 1reatment. Irior lo any
ropairs boing porformod, considoralion slouId bo givon
lo llo nood for a dolydrogonalion loal lroalmonl of
vossoIs or parls llal lavo boon oxposod lo producls
or procossos conlaining lydrogon lo avoid lydrogon
cracIing during ropairs. Dolydrogonalion loal lroal-
monl may bo porformod as oulIinod villin AII RI 934.
4.5.2 mbrittIement. Somo maloriaIs may lavo boon
oxposod lo sorvico condilions llal causo ombrillIomonl
of lloso maloriaIs. Considoralion slouId bo givon lo llo

Fig. 1 weId 5eam with ack CIadding

prior sorvico condilions and llo polonliaI damago in
maloriaIs rosuIling from lloso sorvico condilions. Tlis
may roquiro spociaI voIding procoduros and loclniquos
lo minimizo llo risI of cracIing during voIdod ropairs.
Ior oxampIo, llo uso of voIding procoduros llal provido
conlroIIod doposilion and IovvoIding loal inpul roduco
llo risI of cracIing in ombrillIod baso molaIs during
voIding ropairs.
4.5.3 Intermediate Pwh1. Aflor porforming voId
ropairs lo Iov aIIoy slooI baso molaI, bul boforo appIica-
lion of voId ovorIay (if appIicabIo), a dolydrogonalion
loal lroalmonl or an inlormodialo IWHT slouId bo con-
sidorod, ospociaIIy if llo baso molaI is 2
1
4
Cr or liglor
aIIoy, or loavy vaII (groalor llan 38 mm or 1
1
2
in. llicI).
4.5.4 hardness and 1eughness. Considoralion
slouId bo givon lo llo maximum lardnoss and lougl-
noss noodod in voId molaI and in baso molaI
loal-affoclod zonos for llo inlondod sorvico.
4.6 5urIace PreIiIe
Iinislod surfacos slouId bo froo of undorcul, nolclos,
slarp ridgos, and abrupl surfaco clangos. Grinding may
bo roquirod lo oIiminalo irroguIarilios or pils.
59
4.7 heat 1reatment
4.7.1 CeneraI. Hoal lroalmonl slaII bo porformod
in accordanco vill llo appIicabIo codo of conslruclion,
posl-conslruclion codo, or ovnor-usor spocificalion. As
an aIlornalivo lo loal lroalmonl, and if aIIovod by llo
codo and approvod by llo ovnor, considoralion may bo
givon lo llo uso of aIlornalivos sucl as lompor boad
voIding procoduros.
4.7.2 Prier Pwh1. Considoralion slouId bo givon
lo llo offocl of any prior poslvoId loal lroalmonls
(IWHT) and any addilionaI IWHT for voIdod ropairs
on cIadding and on slrongll and louglnoss of llo baso
molaI and voIdod joinls.
4.7.3 Lew AIIey 5teeIs. In caso of ropairs lo llo
cIadding or voId ovorIay on Iov aIIoy slooIs (o.g.,
Cr-Mo), llo ropairod aroa may bo subjoclod lo finaI
IWHT any limo aflor llo doposilion of 5 mm (
3
16
in.)
of llo firsl Iayor of llo corrosion rosislanl voId doposil
(unIoss anollor dopll is quaIifiod). IinaI IWHT may
bo porformod oillor boforo or aflor llo doposilion of
addilionaI Iayors of ovorIay sinco onIy llo firsl Iayor

of voId doposil viII causo a HAZ in llo baso molaI.
Subsoquonl Iayors of voIding vouId nol bo oxpoclod lo
croalo a nov HAZ in llo baso molaI.
5 XAMIhA1I0h
5.1 CeneraI
5.1.1 hendestructive xaminatien eIere weIding.
Considoralion slouId bo givon lo llo nood for nondo-
slruclivo oxaminalion of surfacos lo bo voIdod. An
approprialo mollod sucl as magnolic parlicIo or Iiquid
ponolranl may bo uliIizod lo onsuro llal aII dofocls lavo
boon romovod boforo llo voIding. Any unaccoplabIo
indicalions llal aro discovorod slaII bo romovod in
accordanco vill ArlicIo 3.4, IIav Ixcavalion and WoId
Ropair, of llis Slandard prior lo appIicalion of voId
ovorIay. Tlo accoplanco criloria slaII bo in accordanco
vill llo appIicabIo codo of conslruclion or
5.1.2 hendestructive xaminatien AIter weIding.
Considoralion slouId bo givon lo llo nood for nondo-
slruclivo oxaminalion of surfacos ropairod by voIding.
Surfaco oxaminalion mollods sucl as magnolic parlicIo,
Iiquid ponolranl, uIlrasonic, or surfaco oddy curronl may
bo uliIizod in accordanco vill llo appIicabIo codo of
conslruclion or posl-conslruclion codo. WoIds on baso
molaI ovor 9.5 mm (
3
8
in.) llicI slouId bo oxaminod by
voIumolric oxaminalion mollods sucl as radiograplic
or uIlrasonic losling. Tlo accoplanco criloria slaII bo in
5.2 Cepper 5uIIate 5eIutien 1esting
Aflor romovaI of any damagod slainIoss slooI voId
ovorIay, and prior lo appIying nov voId molaI, carbon
slooI surfacos slouId bo oxaminod vill coppor suIfalo
soIulion lo vorify compIolo romovaI of slainIoss slooI.
(Soo ASTM A 380 for coppor suIfalo losling).
5.3 Liquid Penetrant xaminatien eI weId 0verIay
and ack CIadding
5.3.1 MuItipIe-Layer weIds. Ior muIlipIo-Iayor voId
ovorIay or bacI cIadding, Iiquid ponolranl oxaminalion
slouId bo porformod on llo firsl Iayor of llo voId
ovorIay.
5.3.2 Finished 5urIaces. Tlo finaI surfaco of voId
ovorIays, bacI cIadding, and voIds joining allaclmonls
lo voId ovorIays or inlograI cIadding slouId bo Iiquid
ponolranl oxaminod lo an approprialo oxlonl.
5.3.3 xaminatien and Acceptance 5tandards.
Ixaminalion and accoplanco slandards slaII bo in accor-
danco vill llo appIicabIo codo of conslruclion or
posl-conslruclion codo. If no slandard is spocifiod by
codo, llo oxaminalion may bo conduclod in accordanco
60
vill ASMI BIVC Soclion V, and accoplanco criloria
may bo in accordanco vill Appondix 8 of ASMI BIVC
Soclion VIII, Division 1. Dofoclivo aroas slaII bo ropairod
and rooxaminod.
6 151IhC
6.1 ChemicaI AnaIysis
6.1.1 Precedure uaIiIicatien. Tlo clomicaI compo-
silion al llo offoclivo dopll of llo ovorIay or bacI
cIadding slouId bo incIudod in voIdingprocoduro quaIi-
ficalion losls.
6.1.2 Preductien weIding. AIlornalivoIy, llo clomi-
caI composilion al llo offoclivo dopll of llo ovorIay or
bacI cIadding slaII bo roporlod for produclion voIding,
vlon spocifiod by llo ovnor. Tlo accoplanco criloria
for produclion ovorIay and bacI cIadding slaII bo in
accordanco vill llo ovnors spocificalion oxcopl as
nolod in llis documonl.
6.1.3 xtent eI Chemistry and Ferrite 1esting
Tlo numbor of sampIos for clomicaI anaIysis for
aII lypos of voId ovorIay and bacI cIadding, and numbor
of forrilo moasuromonls for auslonilic slainIoss slooI
doposils, slaII bo as spocifiod by llo ovnor. Wlon
roquirod, losl sampIos slouId bo romovod, or in silu
losls slouId bo conduclod, prior lo finaI IWHT (if appIi-
cabIo) al Iocalions soIoclod by llo fioId inspoclor. Tosling
aflor IWHT is nol roquirod unIoss ollorviso spocifiod
by llo ovnor.
Ior maclino voId ovorIay, ono sampIo or losl
from oacl girll voId and compononl (sucl as load,
luboslool, connoclion, olc.), and oacl bacI-cIad soam is
rocommondod. Ior manuaI voId ovorIay, lvo sampIos
or losls from oacl girll voId and oquipmonl compononl
(sucl as load, luboslool, connoclion, olc.), and oacl
bacI-cIad soam aro rocommondod.
Ior bacI-cIad soams 600 mm (24 in.) in diamo-
lor, ono sampIo for oacl 24 diamolraI-incl, or parl
lloroof, is rocommondod. Tlo 24 diamolraI-incl moa-
suromonl is cumuIalivo for aII bacI-cIad soams 600 mm
(24 in.) diamolor and smaIIor ompIoying llo samo voId-
ing procoduro, procoss, and fiIIor molaI.
IXAMIII: Ono 20 in. manvay and llroo 8 in. nozzIos 44
diamolraI-inclos, or ono 500 mm manvay and llroo 200 mm
nozzIos 1 100 mm diamolor moasuromonl. Tloroforo, lvo losls
aro roquirod.
Ior ropolilivo manuaI, somi-aulomalic, and aulo-
malic voId ovorIay oporalions on compononls 600 mm
(24 in.) diamolor, lvo losls por voIdor por vooI may bo
subslilulod for llo roquiromonls of (a)(1) abovo. Hov-
ovor, lloro slaII bo no clango in voIding procoduro,
fiIIor molaI cIassificalion, balcl numbor of submorgod
arc or oIoclrosIag fIux, or voIding posilion. Aulloriza-
lion slaII bo al llo discrolion of llo ovnor.

6.2 ChemicaI Cempesitien eI Austenitic 5tainIess
5teeI weId epesits
Tlo clomicaI anaIysis slaII bo villin llo rango spoci-
fiod in llo originaI codo of conslruclion, or in ASMI
BIVC Soclion II, Iarl C.
6.3 Ferrite 1esting eI Austenitic 5tainIess 5teeI weId
epesits
Suggoslod roquiromonls for auslonilic slainIoss slooI
forrilo numbors aro as foIIovs:
Tlo forrilo conlonl of llo doposilod voId ovorIay
or bacI cIadding al llo offoclivo dopll (as dofinod in
soclion 1 of llis ArlicIo) slouId bo as foIIovs:
Ior Typo 304, 304I, 316, 316I, and 317I, llo IN
rango slouId bo 4 lo 10.
Ior Typo 347, llo IN rango slouId bo 3 lo 10.
Tlo forrilo conlonl slouId bo dolorminod by ono
of llo foIIoving:
Tlo acluaI, as-doposilod clomicaI composilion
and llo WRC-1992 Conslilulion Diagram
Magnolic inslrumonl as Iislod in AWS
A4.2/A4.2M.
6.4 CaIibratien eI Magnetic Ferrite 1esting Cages
Magnolic gagos slouId bo caIibralod and corlifiod
por AWS A4.2/A4.2M. An annuaI caIibralion corlifica-
lion slouId bo avaiIabIo lo llo inspoclor. Irior lo uso in
produclion, inslrumonl caIibralion slouId bo vorifiod
on al Ioasl lvo slandards (caIibralion losl bIocIs) vill
a minimum forrilo sproad of 5 IN. Al Ioasl ono of lloso
slandards slouId lavo a IN of 4 lo 10.
Tloso slandards slouId bo ono of llo foIIoving:
primary or socondary voId molaI slandards
doscribod in AWS A4.2/A4.2M
sampIos vill corlifiod clomicaI anaIysos rofor-
oncod lo llo WRC-1992 (IN) Diagram or llo DoIong
(IN) Diagram
sampIos vill forrilo conlonl moasurod by molaI-
Iograplic loclniquos
6.5 Ferricyanide 1esting eI hiCu (AIIey 400) and
Cuhi AIIeys
Iorricyanido losling slouId bo porformod on aII
nicIoIcoppor |AIIoy 400 (MonoI), 67Ni30Cu] and
coppornicIoI (70Cu30Ni, 90Cu10Ni) aIIoy ovorIays
and bacI cIadding.
Iorricyanido losls slouId bo porformod on 100
of finislod nicIoIcoppor or coppornicIoI ovorIays and
bacI cIadding doposils. Tlo rosuIls slouId nol indicalo
llo prosonco of froo iron.
Tlo suggoslod losl procoduro is as foIIovs:
Tlo surfaco lo bo oxaminod slouId bo proparod
by a mollod llal doos nol causo conlaminalion by froo
iron. A soIvonl or dolorgonl soIulion slouId romovo oiI,
groaso, and dirl. A picIIing soIulion may bo usod lo
romovo oxidos. Tlo surfaco slouId bo llorouglIy rinsod
61
aflor picIIing or dolorgonl cIoaning, using disliIIod or
do-ionizod valor. If moclanicaI surfaco proparalion is
roquirod, nov omory papor or grinding vlooIs, and
nonforrilic buffing vlooIs and bruslos slouId bo usod.
Suggoslod composilion of llo losl soIulion is as
foIIovs:
90 by voIumo polassium forricyanido (4
soIulion)
10 by voIumo soIulion consisling of 1 parl
conconlralod lydroclIoric acid (36 lo 38 by voigll
HCI) and 9 parls disliIIod valor
Irosl losl soIulion slouId bo proparod immodi-
aloIy boforo appIicalion.
Tlo losl ing soIulions roaclion slouId bo
clocIod on sampIos of nicIoIcoppor or coppornicIoI
and carbon slooI. A bIuo coIor slouId appoar immodi-
aloIy on carbon slooI. No coIor slouId appoar on nicIoI
coppor or coppornicIoI villin 10 min. If coIor doos
appoar, llo soIulion is loo acidic, and nov soIulion
slouId bo formuIalod.
SoIulion slouId bo appIiod lo llo loslod surfaco
by spraying (using an alomizor) or drop-by-drop (using
an oyodroppor). Appoaranco of a dofinilo bIuo coIor
villin 2 min indicalos llo prosonco of froo iron. A Iigll
bIuo linl slouId bo considorod insignificanl.
Quoslions rogarding dolorminalion of iron con-
lonl basod on llo dogroo of bIuonoss slouId bo rosoIvod
by spol clomicaI anaIysis. Tlo iron conlonl slouId nol
oxcood 6.
6.6 hydrestatic 1esting
Tlo inspoclor slouId bo consuIlod lo oslabIisl llo
nood for lydroslalic losling of oquipmonl aflor ropairs
aro compIolo. Irossuro losling is gonoraIIy nol noodod
for voId buiIdup and rosloralion lypo ropairs, bul if
spocifiod, slouId bo in accordanco vill llo codo of con-
7 kFkhC5
AII RI 582, WoIding GuidoIinos for llo ClomicaI, OiI
and Gas Induslrios
AII RI 934, MaloriaIs and Iabricalion Roquiromonls for
2
1
4
Cr-1Mo and 3Cr-1Mo SlooI Hoavy WaII Irossuro
VossoIs for Higl Tomporaluro, Higl Irossuro
Hydrogon Sorvico
Slrool, Waslinglon, DC 20005-4070
Soclion II, Iarl C Spocificalions for WoIding Rods,
IIoclrodos, and IiIIor MolaIs

Soclion V Nondoslruclivo Ixaminalion
Soclion VIII, Division 1 RuIos for Conslruclion of
Irossuro VossoIs
Soclion IX WoIding and Brazing QuaIificalions
Box 2300, IairfioId, N} 07007-2300
ASTM A 380, Slandard Iraclico for CIoaning, DoscaIing,
and Iassivalion of SlainIoss SlooI Iarls, Iquipmonl,
and Sysloms
IubIislor: Amorican Socioly for Tosling and MaloriaIs
(ASTMInlornalionaI), 100 Barr Harbor Road, I.O. Box
C700, Wosl ConslolocIon, IA 19428-2959
62
AWS A4.2/A4. 2M:2006 (ISO 8249: 2000), Slandard
Iraclico for CaIibraling Magnolic Inslrumonls lo
Moasuro llo DoIla Iorrilic Conlonl of Auslonilic and
DupIox Iorrilic-Auslonilic SlainIoss SlooI WoId MolaI
Ropairs of Doaoralors
IubIislor: IIoclric Iovor Rosoarcl Inslilulo (IIRI), 3420
HiIIviov Avonuo, IaIo AIlo, CA 94304
WRC BuIIolin 412, Ropair of a 2
1
4
Cr-1Mo IolroclomicaI
Roaclor
WRC-1992, Conslilulion Diagram for SlainIoss SlooI
WoId MolaIs, KolocIi, D.}. and Siovorl, T.A.

ArticIe 2.12
FiIIet weIded Patches
1 5CkIP1I0h
Tlis ropair mollod doscribos llo soIoclion criloria,
appIicalion Iimilalions, dosign, fabricalion, oxaminalion
and losling of fiIIol voIdod surfaco palclos lo prossuro
rolaining compononls. SimiIar fiIIol voIdod surfaco
palcl ropair mollods vill roinforcing pIug voIds aro
providod in anollor ArlicIo of llis Slandard.
Tlis ropair mollod consisls of filling a ropair pIalo
lo cIosoIy malcl llo originaI compononls oxlorior or
inlorior surfaco. Tlo ropair pIalo is sizod lo covor llo
aroas oxlibiling damago, boll al llo limo of ropair and
llal anlicipalod for llo ropairs dosign Iifo.
Tlo ropair mollod is lypicaIIy appIiod lo prossuro
rolaining sloIIs llal lavo sufforod IocaI vaII llinning
(incIuding llrougl-vaII) duo lo orosion, corrosion and
ollor IocaI damago moclanisms.
Tlis ropair mollod is appIicabIo lo cyIindricaI,
sploricaI, fIal, andconicaI sloIIs as voII as ollor prossuro
compononls.
Tlis ropair mollod is gonoraIIy suilabIo for sorvico
lomporaluros abovo llo niI-ducliIily lomporaluro of llo
maloriaIs of conslruclion up lo a maximum dosign lom-
poraluro of 345C (650I). Uso of llis ropair mollod for
Iovor lomporaluros roquiros ovaIualion of nolcl lougl-
noss, nonducliIo fracluro and ollor appIicabIo Iov lom-
poraluro offocls. Uso of llis ropair mollod for liglor
lomporaluros roquiros ovaIualion of llormaI faliguo,
croop, and ollor appIicabIo ligl lomporaluro offocls.
Iiguro 1 slovs a lypicaI appIicalion on a vossoI
vill a noarby slrucluraI disconlinuily (in llis caso a
nozzIo). Tlo pIan viov on lop slovs lvo of many possi-
bIo ropair palcl configuralions, vlicl aro gonoraIIy roc-
liIinoar in slapo vill roundod cornors. Tlo bollom
soclionaI viov slovs llo curvaluro malcling aspocl of
oacl ropair pIalo.
2 LIMI1A1I0h5
Tlis ropair mollod is nol Iimilod by llo compo-
nonl sizo. Hovovor, a sIoovo lypo ropair may bo moro
suilabIo for lloso appIicalions vloro axisymmolric
bolavior is imporlanl.
Tlis ropair mollod slaII nol bo usod for IollaI
sorvico appIicalions or vloro llo damago moclanism,
llo oxlonl of damago, or IiIoIy fuluro damago cannol
63
bo claraclorizod. Tlis ropair mollod may bo usod in
corl ain casos on aroas vill IocaI cracI-IiIo fIavs
providod
llo grovll las sloppod, boon arroslod, or can
bo accuraloIy prodiclod for aII propagalion modos, and
llo offocl of llo fIav is ovaIualod using dolaiIod
anaIysos.
3 5ICh
3.1 CeneraI
Tlo dosign approacl for llis ropair mollod is
basod in parl on slandard prossuro compononl dosign
caIcuIalions, sucl as lloso in llo ASMI BIV Codo,
Soclion VIII, Division 1. Tlo appIicalion Iimilalions
imposod in soclion 2 appIy lo llo govorning Ioad caso
rosuIling from inlornaI prossuro vloro llo rosuIlanl
slross is mombrano slross. Hovovor, if llo compononl
lo bo ropairod is subjocl lo bonding, lorsion, vind Ioads,
or lo faliguo, llo dosign slaII incIudo ovaIualion of lloso
condilions using approprialo mollods of anaIysis. In aII
casos, an onginooring anaIysis slaII bo porformod.
In gonoraI, llo palcl maloriaI and voIding fiIIor
molaI slouId bo llo samo or vory simiIar (o.g., composi-
lionaI, plysicaI, and moclanicaI proporlios) lo llal of
llo prossuro compononls originaI conslruclion. Ropair
maloriaI soIoclion slaII considor, as a minimum, clarac-
lorislics sucl as clomislry, voIdabiIily, plysicaI propor-
lios (sucl as coofficionl of llormaI oxpansion),
moclanicaI proporlios (sucl as slrongll, ducliIily, nolcl
louglnoss), and compalibiIily vill llo procoss modium.
Tlo llicInoss of llo palcl pIalo is dopondonl on
maloriaI moclanicaI proporlios and llo caIcuIalod
allaclmonl voId sizos.
Tlo sizo (Iongll and vidll) of llo palcl pIalo is
govornod by llo roquiromonl llal aII allaclmonl voIds
bo Iocalod on sound baso molaI compIoloIy oncom-
passing llo damagod aroa(s) (soo Iig. 1). Tlo ropair pIalo
slaII aIso bo Iargo onougl lo oncompass any addilionaI
aroa(s) anlicipalod lo oxporionco simiIar or roIalod dam-
ago during llo Iifo of llo ropair. Tlo palcl pIalo slouId
ovorIap sound baso molaI by al Ioasl 25 mm (1 in.).
Tlis ropair mollod is gonoraIIy usod on llo oul-
sido surfaco of compononls subjocl lo inlornaI prossuro.
Ior appIicalions undor oxlornaI prossuro, a soparalo
(08)

Fig. 1 1ypicaI 5heII kepair hear iscentinuity

64

anaIysis lo ovaIualo bucIIing and ollor inslabiIily con-
sidoralions slaII bo porformod.
In assossing llo appIicabiIily and sorvico Iifo of llis
ropair mollod, considoralion slaII bo givon lo maloriaI
compalibiIily, fuluro oporaling condilions, llormaI and
slrinIago offocls of voIding, llo inlroduclion of crovicos
and slrucluraI disconlinuilios, llormaI lransionls and
lomporaluro difforonliaIs bolvoon llo palcl pIalo and
llo compononl, and ollor appIicalion Iimils sucl as
oxaminalion and losling conslrainls. If llo damago lo
bo palclod is, or is oxpoclod lo bo, llrougl-vaII, llo
offocls of fIuids (o.g., onlrapmonl, conconlralion, corro-
sion, olc.) llal may accumuIalo bolvoon llo vossoI and
llo palcl pIalo slaII bo assossod. If llis ropair mollod
is lo bo impIomonlod during compononl oporalion, addi-
lionaI procaulions may nood lo bo laIon for porsonnoI
safoly.
Tlo dosign may considor llo combinod slrongll
of llo palcl pIalo (considoring aIso llo slrongll of llo
fiIIol voId joinls, incIuding joinl officioncy) and llo
undorIying sloII. Considoralion may aIso bo givon lo
oxcoss llicInoss avaiIabIo adjaconl lo llo damagod sloII
using appIicabIo codo aroa ropIacomonl ruIos for nozzIos.
No crodil slaII bo laIon for maloriaI roquirod for fuluro
corrosion aIIovanco.
3.2 InternaI Pressure Leads
Ior cyIindricaI compononls subjocl lo inlornaI
prossuro Ioads, appIiod forcos on llo ropair palcl slaII
bo dolorminod as foIIovs:
Unil forcos in loop
diroclion:
2
(1)
vloro
diamolor al mid-vaII of compononl, mm (in.)
circumforonliaI forco duo lo inlornaI prossuro,

N/mm (Ib/in.)
inlornaI dosign prossuro, IIa (psi)
65
Unil forcos in IongiludinaI
diroclion:
4
(2)
vloro
IongiludinaI forco duo lo inlornaI prossuro,

N/mm (Ib/in.)
If ollor Ioads aro appIicabIo (sucl as bonding,
lorsion, vind, olc.), lloy slaII bo dolorminod and addod
lo llo prossuro Ioad sucl llal
and
vloro
lolaI circumforonliaI forco from aII Ioads,

N/mm (Ib/in.)
circumforonliaI forco duo lo ollor appIicabIo

lolaI IongiludinaI forco from aII Ioads, N/mm

(Ib/in.)
IongiludinaI forco duo lo ollor appIicabIo

Approprialo aIlornalivo forco caIcuIalions for
sploricaI, lorisploricaI, or oIIipsoidaI prossuro compo-
nonls slaII bo usod vlon appIicabIo.
3.3 5tructuraI iscentinuity vaIuatien
Ior slrossos noar a nozzIo or ollor slrucluraI dis-
conlinuily lo bo insignificanl, llo minimum dislanco
bolvoon llo fiIIol voIdod palcl pIalo and llo oxisling
disconlinuily slouId bo
min
2(
)
1/2
(3)

vloro
min
pIalo sol-bacI dislanco (soo Iig. 1), mm (in.)
radius al mid-vaII of compononl, mm (in.)

vaII llicInoss of compononl, mm (in.)
Tlo faclor of 2 appIios llo sol-bacI dislanco (
)
1/2
lo boll llo oxisling nozzIo (or ollor simiIar slrucluraI
disconlinuily) and llo palcl pIalo.
Tlis proximily Iimil aIso appIios lo llo dislanco
bolvoon adjaconl fiIIol voIdod palcl pIalos, in lloso
appIicalions vloro moro llan ono is ompIoyod on a
givon compononl.
In lloso appIicalions vloro llo palcl pIalo is lo
allacl lo oxisling nozzIo roinforcomonl pads, llo palcl
pIalo may bo conlourod lo malcl llo roinforcomonl pad
porimolor and voIdod llorolo vill a fuII ponolralion
joinl.
In lloso appIicalions vloro llo damagod sloII is
villin
min
of a nozzIo or ollor slrucluraI disconlinuily,
llo palcl pIalo slouId bo dosignod as a roinforcomonl
pad oxlonding 360 dog around llo nozzIo/oponing, and
voIdod llorolo vill a fuII ponolralion joinl. AIlorna-
livoIy, addilionaI dolaiIod anaIysis slaII bo porformod
lo ovaIualo IocaI slrossos.
3.4 AIIewabIe Lead en Perimeter FiIIet weId
Tlo porimolor voId slaII bo sizod sucl llal llo
aIIovabIo Ioad on llo voId oxcoods llo IongiludinaI and
circumforonliaI Ioads.
min
(4)
vloro
voId joinl officioncy faclor (0.55)
aIIovabIo forco on fiIIol voIds, N/mm

(Ib/in.),
and
aIIovabIo baso molaI slross, MIa (psi)

1
min
minimum voId Iog dimonsion, mm (in.)
NOTI: Tlo maximum dosign fiIIol voId sizo slaII nol oxcood llo
llicInoss of llo llinnor maloriaI boing joinod nor 40 mm (1.5 in.).
AIlornalivoIy, llo porimolor voId odgo propara-
lion may bo bovoIod lo incroaso llo voIds offoclivo
llroal llicInoss. In no caso slaII llo offoclivo llroal
oxcood llo llicInoss of llo ropair pIalo or llo originaI
compononl llicInoss.
In addilion, Ioad pall occonlricily of llo loop
slross in llo sloII pIalo and palcl pIalo slaII bo consid-
orod. Tlo porimolor voIds boaring circumforonliaI Ioads
slaII bo sizod sucl llal
1
CompalibIo voId molaI slaII bo of oquaI or groalor slrongll.
66
/2) + (3
/
2
) (5)
vloro
Ioad pall occonlricily ( + )/2, mm (in.)
caIcuIalod voId slross, MIa (psi),
1.5
vaII llicInoss of palcl pIalo, mm (in.)

3.5 CeId Ferming Limits
Carbon and Iov aIIoy slooI palcl pIalos fabricalod
by coId forming slaII nol oxcood 5 oxlromo fibor oIon-
galion. Tlo oxlromo fibor oIongalion slaII bo dolorminod
as foIIovs:
Ior doubIo curvaluro
75
5 (6)
vloro
finaI conlorIino radius of palcl pIalo, mm (in.)
originaI conlorIino radius of palcl pIalo (oquaIs

infinily for fIal pIalo), mm (in.)
llicInoss of llo palcl pIalo, mm (in.)
Ior singIo curvaluro
50
5 (7)
Ialclos coId formod boyond lloso Iimils may bo
usod providod lloy rocoivo approprialo posl-forming
slross roIiof prior lo inslaIIalion.
4 FAkICA1I0h
IIalo odgos may bo cul lo slapo and sizo by
moclanicaI moans sucl as maclining, sloaring, grind-
ing, or by llormaI moans sucl as fIamo or arc culling.
If llormaI moans aro usod, a minimumof 1.5 mm(
1
16
in.)
addilionaI maloriaI slaII bo romovod by grinding or
maclining. If llo ropair pIalo is groalor llan 25 mm
(1 in.) llicI, and llo fiIIol voId sizo is Ioss llan llo pIalo
llicInoss, llo voId prop odgos slaII bo oxaminod by
magnolic parlicIo (MT) or Iiquid ponolranl (IT) mollods
lo clocI for Iaminalions. Iaminalions slaII bo causo for
rojoclion unIoss ropairod or found accoplabIo by
filnoss-for-sorvico anaIysis in accordanco vill
AII 579-1/ASMI IIS-1.
Tlo palcl pIalo may bo formod lo llo roquirod
slapo by any procoss llal viII nol unduIy impair llo
moclanicaI proporlios of llo palcl pIalo maloriaI. Wloro
roquirod duo lo ropair pIalo sizo or accoss/inlorforonco

considoralions, spIil soclions may bo usod vlon joinod
by fuII ponolralion voIds.
Iarls lo bo fiIIol voIdod slaII bo fil as ligllIy as
praclicaI lo llo surfaco lo bo voIdod and in no ovonl
slaII bo soparalod by moro llan 5 mm (
3
16
in.). If llo
soparalion al llo faying odgo of llo pIalo is 1.5 mm
(
1
16
in.) or groalor, llo sizo of llo porimolor fiIIol voId
slaII bo incroasod by llo amounl of llo soparalion.
WoIding procoduros, voIdors and voIding opora-
lors slaII bo quaIifiod in accordanco vill llo curronl
BIV Codo, Soclion IX may bo usod for procoduro and
porformanco quaIificalion. Guidanco for proloal and/
or poslvoId loal lroalmonl, and for in-sorvico voIding,
as appIicabIo, slaII bo laIon from llo appIicabIo codo
IioId ropair aclivilios slouId conform lo llo foI-
Ioving soquonco:
Iainl, scaIo, rusl, Iiquids and ollor foroign malo-
riaI slaII bo romovod from llo voId zono and an aroa nol
Ioss llan 40 mm (1
1
2
in.) on oillor sido of llo voIdmonl.
In lloso aroas llal viII bo covorod by llo nov
palcl pIalo, oxisling sloII soam or girll voIds slaII bo
ground fIusl vill llo vossoI or pipo O.D. and slaII bo
oxaminod by llo MT or IT mollod.
Tlo nov palcl pIalo may bo pIacod in posilion
using any suilabIo mollod.
Any soams villin llo palcl ilsoIf, slouId bo
mado firsl. Tlo porimolor fiIIol voId may llon bo com-
pIolod. CIamps or vodgos may bo usod lo onsuro propor
joinl aIignmonl and fil-up.
Ixposod molaI surfacos slaII bo rocoalod, if appIi-
cabIo, aflor compIolion of aII oxaminalion and losling.
To procIudo gas prossuro buiIdup bolvoon llo
palcl pIalo and llo prossuro compononl boundary, pro-
visions for vonling during llo finaI cIosuro voId or, if
appIicabIo, poslvoId loal lroalmonl, may bo nocossary.
If llo palcl pIalo is dosignod for llrougl-vaII dofocls
bul appIiod lo llo prossuro boundary boforo boing
broaclod, llo vonl slouId bo soaIod aflor compIolion of
voIding and, if appIicabIo, poslvoId loal lroalmonl.
5 XAMIhA1I0h
Ialcl pIalo allaclmonl voIds slaII bo oxaminod
in accordanco vill llo appIicabIo codo of conslruclion
or posl-conslruclion codo by oillor llo MT or IT moll-
ods. If nol ollorviso spocifiod by llo appIicabIo codo
of conslruclion or posl-conslruclion codo, NDI slaII bo
porformod using procoduros vrillon and quaIifiod in
accordanco vill ASMI BIVC Soclion V.
If Iifling Iugs aro usod and Iofl in pIaco, lloir
allaclmonl voIds slaII bo oxaminod by MT or IT moll-
ods. Al aII Iocalions vloro lomporary Iifling Iugs,
67
voIdod cIamps, and/or vodgos aro romovod aflor palcl
pIalo inslaIIalion, llo romovaI aroas slaII bo oxaminod
by MT or IT mollods.
WoIds joining soclions of palcl pIalos mado of
soparalo piocos slouId bo surfaco conlourod and voIu-
molricaIIy oxaminod by oillor radiograplic or uIlrasonic
oxaminalion mollods lo llo oxlonl possibIo. If nol pracli-
cabIo, muIli-Iayor IT or MT oxaminalions slouId bo
porformod.
If poslvoId loal lroalmonl is roquirod, llo oxami-
nalion slaII bo porformod aflor appIicalion of IWHT.
Tlo oxaminalion accoplanco criloria of llo appIica-
bIo codo of conslruclion or posl-conslruclion codo slaII
appIy.
6 151IhC
Tosling slaII bo porformod in accordanco vill llo
Tlo prossuro compononl and inslaIIod palcl
pIalo(s) slouId bo IoaI loslod in accordanco vill llo
appIicabIo posl-conslruclion codo. SpociaI safoly procau-
lions slouId bo laIon vlon pnoumalic IoaI losling is
porformod.
If pormillod by llo appIicabIo posl-conslruclion
codo, nondoslruclivo oxaminalion may bo porformod as
an aIlornalivo lo IoaI losling. AIso, an iniliaI sorvico
inspoclion may bo porformod of aII voId joinls aflor llo
prossuro compononl las rolurnod lo normaI oporaling
prossuro and lomporaluro.
Tosling and inspoclions slouIdbo porformod prior
lo roappIicalion of coaling, insuIalion, or jacIoling, as
appIicabIo.
7 kFkhC5
AII 579-1/ASMI IIS-1, Iilnoss-for-Sorvico, }uno 5, 2007
Division 1 RuIos for Conslruclion of Irossuro
VossoIs
QuaIificalion Slandard for WoIding and Brazing
Irocoduros, WoIdors, Brazors, and WoIding and
Brazing Oporalors
Box 2300, IairfioId, N} 07007-2300
(08)

ArticIe 2.13
1hreaded er weIded PIug kepairs
1 5CkIP1I0h
Tlis ropair mollod doscribos rosloralion of a compo-
nonl or syslom by romoving a fIav or dofocl llrougl
llo driIIing or maclining of a loIo villoul ropIacing
llo compononl maloriaI. IoaI and prossuro ligllnoss
is acliovod by insorling a soIid or llroadod pIug and
appIying a soaI voId. Tlo prosonco or romovaI of dofocls
nood nol bo invoIvod. Tlis mollod may aIso bo usod
lo gain accoss lo a compononl, insido or oulsido, for
inspoclion or ollor purposos.
2 LIMI1A1I0h5
2.1 CeneraI
2.2 kepairs
Il is nol inlondod for llis ArlicIo lo bo usod for roulino
ropair of voId dofocls or for silualions vloro llo condi-
lion can bo romovod by oxcavaling maloriaI and Ioaving
llo compononl as is.
2.3 Cerresien
Tlis ropair mollod gonoraIIy croalos a crovico and is
lloroforo nol suilabIo for sorvico onvironmonls llal may
bo subjocl lo crovico corrosion.
3 5ICh
3.1 esign keview
A llorougl onginooring roviov of llo dosign slaII bo
undorlaIon lo vaIidalo llo appIicabiIily of llis mollod
for rosloring inlogrily lo a compononl or syslom. As a
minimum, llo foIIoving slaII bo considorod:
nood for soaI voIding vs. llroadod pIug
unroinforcod vs. roinforcod configuralions
considoralion of uso of gamma pIugs usod for
radiograplic inspoclion
Iiguro 1 iIIuslralos a lypicaI pIug arrangomonl.
3.2 MateriaI Preperties
IIug maloriaI slouId lavo simiIar slrongll, llormaI
oxpansion proporlios, and aIIoy conlonl as llo originaI
compononl maloriaI. Uso of dissimiIar maloriaIs slouId
68
bo avoidod unIoss ovaIualod and juslifiod in llo ongi-
nooring roviov.
3.3 0pening keinIercement
Roinforcomonl of llo oponing slaII bo dosignod lo
compIy vill llo appIicabIo conslruclion or
3.4 5trength kequirements
Tlroad sizo, pilcl, ongagomonl, olc. (for llroadod
pIugs), and voId sizo (for unllroadod pIugs) slaII pro-
vido salisfaclory Ioad carrying abiIily lo mool llo
slrongll roquiromonls of llo appIicabIo conslruclion or
3.5 5trength and Cerresien Censequences
Slrongll and corrosion (crovico, dissimiIar maloriaIs,
olc.) consoquoncos slouId bo ovaIualod vill rospocl lo
using soIid vorsus llroadod pIugs. Tlo offocl of sorvico
on dolorioralod llroads vorsus a prossuro rolaining voId
slouId bo considorod.
3.6 MateriaI kemevaI
Tlo amounl of maloriaI llal is lo bo romovod, llo
rosuIling romovaI aroa (Iocalion, oxlonl, and configura-
lion), and mollod lo rosloro inlogrily (smooll pIug,
llroadod pIug, roinforcomonl, olc.) slaII bo addrossod
in llo dosign roviov.
3.7 Finish imensiens
Tlo finisl loIo diamolor or configuralion (aflor driII-
ing, llroading, or laporing, olc.) slaII bo dolorminod by
onginooring anaIysis.
4 FAkICA1I0h
4.1 FIaw Lecatien
Tlo fIav or aroa of inlorosl slaII bo Iocalod, claraclor-
izod and sizod by uIlrasonic or ollor suilabIo moans.
4.2 FIaw kemevaI
Tlo fIav or gonoraI aroa slouId bo romovod by driII-
ing or maclining a circuIar, llrougl-llicInoss loIo.
4.3 PIug Fabricatien
A pIug slaII bo fabricalod in accordanco vill llo
dosign spocificalion.

Fig. 1 1ypicaI PIug Arrangement

6FhFkAL hUTF: use cf ccunterbcres (as shcwn) typlcally reduce restralnt cn the seal welds and mlnlmlze cracklng.
69

4.4 Lubricants
Tlroad Iubricanl or lapo is gonoraIIy nol usod vill
llroadod pIugs in oIovalod lomporaluro sorvico.
4.5 PIug Insertien
Insorlion (or scrov) of llo pIug slaII bo vorifiod for
fil-up and/or ligllnoss in accordanco vill llo dosign
spocificalion.
4.6 5eaI er FiIIet weIding
A soaI voId or slrongll fiIIol voId slaII bo appIiod
using a quaIifiod voIding procoduro in accordanco vill
llo appIicabIo conslruclion or posl-conslruclion codo.
5 XAMIhA1I0h
5.1 FIaw kemevaI veriIicatien
Wloro a loIo and subsoquonl pIug aro usod lo oIimi-
nalo a fIav or dofocl, romovaI slaII bo vorifiod as
roquirod by llo appIicabIo conslruclion or
A surfaco oxaminalion slaII bo porformod on llo com-
pIolod soaI or roinforcing fiIIol voId in accordanco vill
and if roquirod by llo appIicabIo conslruclion or
5.3 ecumentatien
Tlo inspoclion, as spocifiod in llo govorning projocl
documonls, slaII bo documonlod.
70
6 151IhC
IoaI, ligllnoss, or prossuro (lydroslalic or pnou-
malic) losling slaII bo porformod in accordanco vill
and, if roquirod, by llo appIicabIo conslruclion or
posl-conslruclion codo. Irosorvico inspoclion for IoaIs
during slarlup may bo porformod as an aIlornalivo if
pormillod by llo appIicabIo codo. Soo ArlicIo 5.1.
7 kFkhC5
Soclion I, Iovor BoiIors
Soclion VIII, Division 1, RuIos for Conslruclion of
Irossuro VossoIs
Soclion IX, WoIding and Brazing QuaIificalions
Box 2300, IairfioId, N} 07007-2300
III IS-16, Accoss HoIos, Bossos and IIugs for
Radiograplic Inspoclion of Iipo WoIds
IubIislor: Iipo Iabricalion Inslilulo (III), 666 Iifll
Avonuo, Nov YorI, NY 10103

PAk1 3
MChAhICAL kPAIk5
ArticIe 3.1
kepIacement eI Pressure Cempenents
1 5CkIP1I0h
Tlis ArlicIo appIios lo llo ropIacomonl of prossuro
oquipmonl or piping compononls (sucl as vossoIs,
vaIvos, inslrumonls, fillings, fIango gasIols, olc.) or sub-
assombIios (sucl as pipo spooIs, vossoI loads, sloIIs,
olc.). Tlo ropIacomonl may bo a ropIacomonl in Iind
(ropIacomonl by idonlicaI compononls) or a modificalion
(a clango in maloriaIs, dosign, or fabricalion).
2 LIMI1A1I0h5
3 5ICh
3.1 Mitigatien
If llo ropIacomonl is duo lo dolorioralion, llo causo
of llo dolorioralion and llo nood lo maIo clangos lo
miligalo fuluro dolorioralion slouId bo considorod.
3.2 ngineering vaIuatien
An onginooring ovaIualion slaII bo porformod if lloro
is any clango from llo originaI dosign. Tlo dosign ongi-
noor slaII spocify llo funclionaI, maloriaI, and moclani-
caI roquiromonls for llo ropIacomonl compononl or
subassombIy. IunclionaI roquiromonls incIudo procoss
variabIos, fIov claraclorislics, olc. MaloriaI roquiro-
monls incIudo cloico of maloriaIs compalibIo vill llo
procoss and vill llo oxisling syslom, cloico of maloriaI
spocificalion, maloriaI quaIily, olc. MoclanicaI roquiro-
monls incIudo vaII llicInoss, prossuro cIass, Iayoul, sup-
porls, olc.
3.3 esign Cede
Tlo moclanicaI dosign of llo ropIacomonl compononl
or subassombIy slaII compIy vill llo appIicabIo codo
71
3.4 MediIicatiens
Il may bo nocossary lo modify llo dosign of llo
oxisling syslom lo accommodalo llo ropIacomonl. Ior
oxampIo, ropIacing a vaIvo vill a loavior ono may
roquiro adding addilionaI supporls or Iargo culouls in
vossoI sloIIs or ropIacomonl of sloIIs may roquiro lompo-
rary roslrainls or supporls.
4 FAkICA1I0h
4.1 5aIety
IIanning and impIomonlalion of ropIacomonl aclivi-
lios slaII llorouglIy and cIoarIy accounl for propor iso-
Ialion, IocIoul and lagoul, drainago, vonling and
cIoaning of sysloms or compononls, in accordanco vill
rocognizod and accoplod onginooring praclicos, roguIa-
lions, and approprialo safoly procoduros.
4.2 weIding
Tlo voIding (incIuding voIding procoss and proco-
duro, maloriaIs, quaIificalion, provoId and poslvoId
loal lroalmonl) or moclanicaI joining loclniquo of llo
ropIacomonl compononl or subassombIy slaII compIy
vill llo appIicabIo codo of conslruclion or posl-
conslruclion codo.
4.3 1ie-in [eint
Tlo lio-in joinl (joinl bolvoon llo ropIacomonl parl
and llo oxisling compononl) slaII bo cIoanod and mado
suilabIo for joining. Tlo oxisling compononl al llo lio-
in slouId oxlibil no ovidonco of dolorioralion from llo
originaI maloriaI llicInoss, compIying vill llo appIica-
bIo codo of conslruclion or posl-conslruclion codo,
unIoss juslifiod by an approprialo IovoI of filnoss-for-
sorvico ovaIualion.
4.4 eIted [eint
Ior llo assombIy of boIlod joinls, slandards sucl as
ASMI ICC-1 slouId bo foIIovod.

5 XAMIhA1I0h
5.1 Criteria
Nov joinls and joinls bolvoon nov and oId maloriaI
slaII bo oxaminod in accordanco vill llo appIicabIo
codo of conslruclion or posl-conslruclion codo, incIud-
ing lypo, oxlonl and Iocalion of oxaminalion, and accopl-
anco criloria.
5.2 MechanicaI 1ie-in
Tlo oxaminalion of moclanicaI lio-in joinls (sucl as
fIangos, llroadod joinls, svago or comprossion filling,
and lubo fillings) slouId bo spocifiod by llo ovnor and
may consisl of llo vorificalion of propor joining procoss
and finaI assombIy, or ligllnoss clocIs by lorquo vroncl
or gagos vloro appIicabIo (go/no-go gagos, lorquing of
fIangos boIls).
6 151IhC
6.1 Criteria
Tlo nov compononl or subassombIy slaII bo prossuro
loslod and/or oxaminod as roquirod or aIIovod by llo
codo.
6.2 AIternative
Wloro il is impraclicaI lo porform a lydroslalic pros-
suro losl for llo voIdod or moclanicaI lio-in joinls, llo
organizalion porforming llo vorI may subslilulo llo
lydroslalic prossuro losl vill a losl mollod llal viII
vorify llo IoaI inlogrily of llo joinl. Ior oxampIo, an
aIlornalivo losl mollod for lydroslalic losling may bo
a pnoumalic losl (soo para. 6.2.1). Wlon aII safolyprocau-
lions cannol bo mol or vlon prossuro or IoaI losling is
impraclicaI lo porform, nondoslruclivo oxaminalion
may bo usod (soo para. 6.2.2).
6.2.1 If pnoumalic losling is porformod, llo
appIiod prossuro slaII nol oxcood llal aIIovod by llo
72
codo and aII codo-spocifiod safoly procaulions slaII bo
foIIovod.
6.2.2 Wloro nondoslruclivo oxaminalion is usod
in Iiou of prossuro or IoaI losling voIdod lio-in joinls,
voIumolric oxaminalion, sucl as RT or UT, slaII bo por-
formod if configuralion aIIovs for accoplabIo and moan-
ingfuI rosuIls. If voIumolric oxaminalion cannol bo
porformod, ollor mollods, sucl as IT or MT, may bo
porformod prior lo, during, or aflor voIding lo llo oxlonl
noodod lo vorify llo voId conlains no dofocls. Wloro
nondoslruclivo oxaminalion is usod, llo accoplanco cri-
loria of llo appIicabIo codo of conslruclion or posl-
conslruclion codo slaII appIy. Ior moclanicaI lio-in
joinls, llo roquiromonls of paras. 4.4 and 5.2 slouId bo
foIIovod.
6.2.3 AddilionaI prossuro losling roquiromonls,
procoduros, and rocommondalions aro doscribod in
ASMI ICC-2, ArlicIo 5.1.
6.3 esign Change Menitering
IoIIoving a clango in dosign, llo syslom slaII bo
obsorvod for signs of abnormaI vibralion, oxpansion,
conlraclion, or ollor signs of maIfunclion during iniliaI
oporalion.
7 kFkhC5
ASMI ICC-1, GuidoIinos for Irossuro Boundary BoIlod
IIango }oinl AssombIy
ASMI ICC-2, ArlicIo 5.1, Irossuro and Tigllnoss Tosling
of Iiping and Iquipmonl

ArticIe 3.2
Freeze PIugs
1 5CkIP1I0h
1.1 1echnique
A froozo pIug oporalion is a loclniquo for isoIaling a
soclion of piping by cryogonicaIIy cooIing llo oulor vaII
of llo pipo and froozing llo conlainod Iiquid lo form a
soIid pIug. Carbon dioxido and Iiquid nilrogon aro llo
lvo mosl commonIy usod froozo modiums.
1.2 AppIicatien
A froozo pIug can bo porformod on valor, valor soIu-
lions, sIudgo, somo lydrocarbons, somo acids, somo
basos, and somo ollor Iiquids. Iroozo pIugs lavo loId
170 bar (2,500 psi) for acluaI fioId ropairs and succoss-
fuIIy loslod as ligl as 680 bar (10,000 psi). Tlo succoss
of a froozo pIug doponds on llo froozo poinl of llo Iiquid,
llo sizo of llo pipo, llo iniliaI lomporaluro, proximily
of fIovin connocling pipos, andllo piping arrangomonl.
1.3 kisk Assessment
Il slouId bo rocognizod llal vliIo porforming a froozo
pIug, a faiIuro couId occur rosuIling in injury lo porson-
noI or damago lo oquipmonl. Tloroforo, llo ond usors,
in lloir docision procoss, slaII assoss llo bonofils of llo
froozo pIug loclniquo againsl llo possibiIily of a pIug
or pipo faiIuro.
1.4 asis
Tlis ArlicIo is basod on oxporionco vill froozo pIugs
in molaI pipos.
2 LIMI1A1I0h5
2.2 5aIety Censideratiens
2.2.1 0xygen eIicient Atmesphere. Tlo major laz-
ard of vorIing vill Iiquid nilrogon and carbon dioxido
for porforming froozo pIugs is llo possibiIily of asplyxi-
alion in an oxygon doficionl almosploro. Tlis slaII bo
minimizod by foIIoving confinod spaco procoduros
incIuding clocIing llo oxygon conlonl of llo almo-
sploro vill an oxygon anaIyzor. Oxygon moniloring
oquipmonl slouId lavo a visuaI indicalor and an audibIo
aIarm.
73
2.2.2 urns. Irosl burns aro anollor lazardof cryo-
gonic Iiquids and soIids llal slouId bo minimizod by
llo uso of propor procoduros and proloclivo cIolling.
2.2.3 PersenneI. IorsonnoI slaII bo lrainod and
oxporioncod in llo froozo mollod and InovIodgoabIo
of llo lazards of landIing and using cryogonic Iiquids.
IorsonnoI slaII aIso foIIov propor procaulions and pro-
coduros roIalod lo proloclivo cIolling, vonliIalion in con-
finod spacos, moniloring of lomporaluros, moniloring
of oxygon in llo air, omorgoncios, and firsl aid.
2.2.4 CenIined 5pace eIew Crade. Ior froozo pIugs
porformod boIov grado, llo froozo jacIol slouId bo
inslaIIod in a soparalo oxcavalion from llo vorI aroa.
Doing so minimizos llo numbor of individuaIs oxposod
lo nilrogon gas or Iiquid. If llis is nol possibIo, addilionaI
safoly procaulions slaII bo laIon vlicl may incIudo
confinod spaco procoduros for aII porsonnoI.
2.2.5 venting 5aIety. Nilrogon vonls slouId bo lo
llo oulsido or abovo grado and nol inlo llo confinod
spaco. Air movors or fans slouId bo usod lo mainlain
llo frosl air.
2.2.6 CeeIant Leaks. Iiquid nilrogon IoaIs from
llo froozo oquipmonl slouId bo corroclod or minimizod
vlonovor possibIo lo prolocl porsonnoI and oquipmonl.
Confinod spaco procoduros slaII bo foIIovod vlon
appIicabIo. WorI aroas slouId bo barricadod and iso-
Ialod vill larps lo prolocl porsonnoI and oquipmonl
vlon appIicabIo.
2.3 Freeze Peint
Il is imporlanl lo Inov llo froozo poinl lomporaluro
of llo Iiquid boforo porforming a froozo pIug oporalion.
Tlo froozo poinl lomporaluro for mosl procossos can bo
providod by llo ovnor or found in clomicaI roforoncos.
If llis informalion is nol avaiIabIo, a froozo poinl lompor-
aluro losl slouId bo porformod (soo soclion 6).
2.4 hydrecarben Precautiens
A froozo pIug oporalion on lydrocarbons slaII bo
ovaIualod vill spociaI procaulions. Tlo pIug gains
slrongll duo lo an incroaso in viscosily as llo lompora-
luro docroasos. Tlo conlor of llo froozo pIug is al a liglor
lomporaluro llan llo oulsido of llo pIug. Tlis moans
llal llo viscosily is Iovor al llo conlor. Tloroforo, llo
sloar slrongll of llo pIug is Iovor. Tlo lomporaluro
roading from llo llormocoupIos slaII bo sufficionlIy Iov
(08)
(08)
(08)
(08)

llal llo inlornaI lomporaluro of llo pIug is in llo rango
llal providos fuII slrongll of llo froozo pIug. Tlo froozo
poinl/rango lomporaluro losl viII aid in ovaIualing llis
roquiromonl.
2.5 Light nds
If llo fIuid mixluro conlains Iigll onds llal vaporizo
vlon llo dovnslroam soclion is vonlod, llo froozo pIug
viII nol loId. Tlo foasibiIily of a froozo pIug in llis
fIuid can bo dolorminod by porforming a froozo poinl
lomporaluro losl.
2.6 Impact Leading
Tlo piping syslom slouId nol bo subjoclod lo any
significanl dynamic or oxlornaI Ioads during llo froozo
oporalion. Ior oxampIo, do nol uso lammor vronclos
or impacl vronclos lo romovo sluds and nuls. Tlo boIls
or sluds and nuls slouId bo romovod ono al a limo and
cIoanod or ropIacod prior lo llo froozo pIug oporalion
lo minimizo lloso offocls.
2.7 FIew
Tlo pipo lo bo frozon musl bo fuII of Iiquid al llo
Iocalion of llo froozo pIug and a no fIov condilion
musl oxisl. Tlo mosl common causo for faiIuro lo
dovoIop a soIid pIug and a succossfuI froozo is fIov in
llo pipo. Tlis probIom is oxacorbalod by llo facl llal il
is somolimos difficuIl lo dolormino vlollor lloro is a
fIov. Hovovor, somo froozos can bo porformod on smaII
pipos, up lo DN 100 (NIS 4) in sizo, vill a Iov fIov.
2.8 InitiaI FIuid 1emperature
GonoraIIy, llo Iiquid boing frozon slouId bo al an
iniliaI lomporaluro of 50C (120I) or boIov.
2.9 Adjacent FIews
If llo froozo pIug is Iocalod noar a loo, fIov in llo
connocling pipo may provonl llo froozo, duo lo oddy
curronls and llo BornouIIi offocl.
3 5ICh
3.1 Pipe MateriaIs
3.1.1 5uccessIuI AppIicatiens. Iroozo pIugs lavo
boon succossfuIIy porformod on aII commorciaIIy avaiI-
abIo molaIs. Tlis incIudos molaIs llal aro brillIo al nor-
maI, inlormodialo, and cryogonic lomporaluros.
3.1.2 uctiIity. Cryogonic lomporaluros may bo
Iovor llan llo brillIo lransilion lomporaluro for somo
maloriaIs. Ioss of nolcl louglnoss is a spociaI concorn
for carbon slooI, Iov aIIoy slooIs, forrilic and marlonsilic
slainIoss slooIs, and dupIox (auslonilic-forrilic) slainIoss
slooIs. Coppor, aIuminum, auslonilic slainIoss slooIs, and
ligl nicIoI aIIoys Ioso somo ducliIily al cryogonic lom-
poraluros bul gonoraIIy rolain sufficionl nolcl
louglnoss.
74
3.2 MateriaI Preperty Changes
As llo lomporaluro of llo mol aI docroasos, llo
slrongll of llo maloriaI incroasos, bul ils fracluro lougl-
noss docroasos. Tlo microslrucluro and plysicaI propor-
lios of a molaI aro unclangod aflor llo molaI las boon
oxposod lo cryogonic lomporaluros and rolurnod lo nor-
maI lomporaluros.
3.3 Pressure
Tlo prossuro llal a froozo pIug can loId is diroclIy
proporlionaI lo llo slrongll of llo pIug, llo slrongll of
llo pIug is diroclIy proporlionaI lo llo Iongll of llo
pIug, and llo sloar slrongll of llo pIug incroasos as llo
lomporaluro docroasos. Ico conlracls al a faslor ralo llan
slooI as llo lomporaluro docroasos, lloroforo, llo froozo
pIug oxorls no prossuro on llo insido of llo pipo as llo
froozo pIug forms.
3.4 5trength
Iroozo pIugs formod undor liglor prossuro aro
slrongor. If praclicaI, llo froozo pIug slouId bo formod
al llo liglosl prossuro lo bo oncounlorod during llo
oporalion.
3.5 Lecatien
Tlo ond usor slouId ovaIualo llo Iocalion of porma-
nonl and lomporary pipo supporls lo aIIov for oxpan-
sion and conlraclion during llo froozo pIug oporalion.
Tlo onginooring dosign of drains, vonls, prossuro roIiof
poinls, and isoIalion vaIvos slaII aIso bo considorod.
3.6 Liquid hitregen Freeze PIugs
3.6.1 ackgreund. Iiquid nilrogon is llo mosl com-
mon mollod of forming a froozo pIug in a pipo. Tlis
cryogonic fIuid is usod for llo vasl majorily of froozos
bocauso il is roIalivoIy inoxponsivo, roadiIy avaiIabIo,
oasiIy lransporlod, oasiIy slorod, and oasiIy lransforrod
lo llo froozo jacIol.
3.6.2 Line 5ize. Tlo boiIingpoinl for Iiquid nilrogon
roquirod lo froozo valor and many ollor Iiquids. Bocauso
of ils capacily for ligl loal lransfor ralos, Iiquid nilrogon
can bo usod for froozo pIugs in pipo sizos up lo DN 1 200
(NIS 48).
3.6.3 [acket esign. A jacIol, as slovn in Iig. 1,
is usod for llo froozo. Tlo maloriaIs of conslruclion for
froozo pIug jacIols aro slainIoss, aIuminum, and fibor-
gIass. Tlo Iiquid nilrogon inIol vaIvos slouId bo Iocalod
al boll llo bollom and llo lop of llo jacIol. Tlo vaIvo
al llo bollom can aIso bo usod as a Iiquid nilrogon drain.
3.6.4 [acket Length. Tlo Iongll of llo jacIol usod
slouId bo nol moro llan llroo pipo diamolors Iong.
Iongor jacIols slouId nol bo usod, bocauso a doubIo
pIug can form villin llo jacIol rosuIling in a lrappod
Iiquid. SlouId llis occur, ligl prossuro can dovoIop

Fig. 1 hitregen Freeze PIug AssembIy

hUTFS:
(1) Thermcccuples
(2) hltrcgen gas vents
(3) Llquld nltrcgen supply
(/) Thermcccuple (cptlcnal)
(5) Freeze |acket
(6) Llquld nltrcgen supply and |acket draln
(7) Temperature mcnltcr
75

bolvoon llo pIugs and rupluro or damago llo pipo. Ior
llo samo roason, lvo jacIols pIacod ond-lo-ond slouId
nol bo usod.
3.6.5 [acket Pressure. Iroozo pIug jacIols aro
dosignod lo oporalo al almosploric prossuro. Tlo ovapo-
raling gas from llo Iiquid nilrogon is vonlod oul llo lop
of llo jacIol lo a safo Iocalion in llo almosploro.
3.6.6 Cempenent MateriaIs. Tlo froozo pIug jacIol,
losos, piping, and vaIvos slouId bo suilabIo for cryo-
gonic lomporaluros.
3.6.7 Menitering. Tlo progross of llo froozo pIug
oporalion is monilorod vill a lomporaluro gago con-
noclod lo llo llormocoupIos Iocalod on llo pipo al oacl
ond of llo jacIol. An oplionaI probo in llo conlor of llo
j acIol may bo usod lo indicalo llo jacIol/pipo
lomporaluro.
3.6.8 AIarms. Tlo oIoclricaI signaI from llo lompor-
aluro gago can aIso bo usod lo lriggor audibIo and visuaI
aIarms lo varn oporalors and mainlonanco porsonnoI of
oillor a nilrogon IovoI docroaso or a lomporaluro incroaso
abovo sol poinl, or boll.
3.6.9 CriticaI AppIicatiens. In somo crilicaI appIica-
lions addilionaI moasuros may bo laIon, incIuding llo
uso of fIovmonilors, difforonliaI prossuro monilors, and
romolo TV camoras lo monilor various aspocls of llo
froozo.
3.7 Carben iexide Freeze PIugs
3.7.1 5ize Limit. Carbon dioxido is usod for froozo
pIugs in pipo sizos up lo DN 100 (NIS 4).
3.7.2 5aIety. Carbon dioxido is oflon usod for froozo
pIugs on valor Iinos in buiIdings bocauso of llo roducod
safoly risI. Hovovor, propor safoly procaulions slaII bo
foIIovod, vlicl may incIudo confinod spaco procoduros.
3.7.3 [acket esign. Tlo jacIol for llis loclniquo
may bo mado of cIoll vrappod around llo pipo and
loId in pIaco by dravslrings on oacl ond. Wlon Iiquid
carbon dioxido is inlroducod inlo llo jacIol, il forms dry
llo pipo.
3.7.4 [acket Length. Tlo Iongll of llo jacIol usod
slouId bo nol moro llan llroo pipo diamolors Iong.
Iongor jacIols slouId nol bo usod, bocauso a doubIo
pIug can form villin llo jacIol rosuIling in a lrappod
Iiquid. SlouId llis occur, ligl prossuro can dovoIop
bolvoon llo froozo pIugs and rupluro or damago llo
pipo. Ior llo samo roason, lvo jacIols pIacod ond lo
ond slouId nol bo usod.
3.7.5 Menitering. A lomporaluro monilor allaclod
lo llormocoupIos al oacl ond of llo jacIol is usod lo
monilor and conlroI llo froozo pIug.
76
3.7.6 Maintaining PIug. AddilionaI injoclions of car-
bon dioxido inlo llo jacIol may bo roquirod lo mainlain
llo froozo pIug.
4 FAkICA1I0h
4.1 Precedures
Wrillon procoduros, covoring llo froozo pIug opora-
lion, porsonnoI roquiromonls, safoly, and conlingoncy
pIans, slouId bo proparod and roviovod by approprialo
porsonnoI prior lo llo slarl of llo job.
4.2 CempatibiIity
Tlo froozo poinl of llo Iiquid in llo pipo slaII bo in
an accoplabIo rango consislonl vill llo froozo modium
and oquipmonl boing usod.
4.3 CeeIant 5uppIy
An adoqualo suppIy of nilrogon or carbon dioxido
slouId bo avaiIabIo for porforming llo job. Iargo froozos
or Iong loId limos may roquiro oillor an on-silo slorago
lanI or addilionaI doIivorios of nilrogon or carbon diox-
ido, or boll.
4.4 InsuIatien and Ceatings
InsuIalion and maslic coalings slaII bo romovod from
llo pipo in llo aroa lo bo frozon lo aIIov inslaIIalion
of llo jacIol and llormocoupIos. Il is nol nocossary lo
romovo llin coalings sucl as painl.
4.5 nvirenment
InvironmonlaI condilions may affocl llo froozo pIug
oporalion. Tloroforo, llo froozo pIug oquipmonl slouId
bo slioIdod from llo vind, rain, and loal sourcos sucl
as llo sun, lol pipos, and lol oquipmonl.
4.6 CIesed 5ystems
SpociaI procaulions slaII bo laIon lo provonl damago
lo llo piping syslom vlon llo froozo pIug oporalion is
Iocalod noar a cIosod ond sucl as a voId cap, bIind
fIango, or cIosod vaIvo. Onco llo froozo pIug is formod,
llo difforonliaI oxpansion of llo ico forming from llo
Iiquid can causo an incroaso in prossuro in llo cIosod
voIumo and damago llo pipo.
4.7 keIated quipment
IvaIualion of oquipmonl, sucl as pumps llal can
causo a prossuro surgo, slouId bo mado in llo pIanning
slago of llo froozo pIug oporalion. Wlonovor possibIo,
llis oquipmonl slouId bo isoIalod for llo duralion of
llo job.
4.8 InstaIIatien
Tlo froozo pIug oquipmonl slaII bo inslaIIod on llo
pipo por llo procoduro.
4.9 Menitering 1ime Frame
Tlo froozo pIug oporalion slaII bo monilorod conlinu-
ousIy from llo limo Iiquid nilrogon or Iiquid carbon
dioxido is inlroducod inlo llo jacIol lo llo compIolion
of aII vorI.

4.10 PIug veriIicatien
Tlroo indicalors slaII bo vorifiod lo onsuro adoqualo
slrongll of llo froozo pIug boforo oponing llo syslom
and porforming vorI.
Tlo primary indicalor is llo lomporaluro roading
al oacl ond of llo jacIol, vlicl slaII bo al or boIov llo
prooslabIislod sol poinl lomporaluro.
A fuII circIo frosl ring slouId dovoIop on oacl ond
of llo jacIol.
A losl of llo froozo pIug slaII bo conduclod al or
abovo llo liglosl prossuro llal viII bo oncounlorod.
Tlo losl of llo froozo pIug can bo porformod by cracI-
ing a fIango, oponing a vaIvo, or lol-lapping a loIo in
llo pipo lo roIoaso llo prossuro on llo dovnslroam sido,
llus uliIizing llo prossuro on llo upslroam sido of llo
pIug for llo losl. In ordor lo onsuro llo inlogrily of llo
froozo pIug boforo llo pipo is fuIIy oponod and vorI
bogins, llo losl slaII bo mainlainod for llo limo poriod
proscribod in llo procoduros. Hydrocarbon producls
slouId bo prossuro loslod for a Iongor poriod of limo
lo onsuro llal a froozo pIug of adoqualo slrongll las
formod.
4.11 Leakage
If procoss IoaIago is obsorvod aflor draining llo dovn-
slroam porlion of llo pipo, llo sourco of IoaIago slaII
bo idonlifiod. If llo IoaIago is from llo froozo pIug,
conlinuo llo froozo. If from a difforonl sourco, llo IoaI
slouId bo ovaIualod and corroclod or if doomod loIora-
bIo, llo vorI can bo porformod.
4.12 weIding
Wlon voIding noar llo froozo pIug, spociaI proco-
duros and procaulions slaII bo foIIovod lo provonl moIl-
ing and faiIuro of llo pIug.
4.13 uratien
Tlo froozo pIug oporalion slaII conlinuo unliI llo pip-
ing syslom is socuro and llo oquipmonl ovnor or lis
roprosonlalivo aullorizos slopping.
4.14 1esting
Boforo pulling llo syslom bacI in sorvico, llo froozo
pIug may bo usod for prossuro losling nov compononls.
4.15 keturn te 5ervice
Wlon llo vorI is compIolod, llo dovnslroam pipo
slouId bo bacIfiIIod, llo prossuro oquaIizod, and llo air
in llo pipo romovod al a ligl poinl vonl.
4.16 1hawing
Tlo rocommondod mollod for romoving llo froozo
pIug is lo aIIov il lo llav naluraIIy. Tlis viII minimizo
llo risI of il moving dovnslroam and damaging llo
piping syslom. Il is gonoraIIy nol rocommondod lo appIy
loal lo llo pipo lo spood llaving of llo pIug.
77
5 XAMIhA1I0h
5.1 visuaI Inspectien
Tlo pipo in llo froozo pIug Iocalion slouId bo visuaIIy
inspoclod for dofocls, gougos, oxlornaI corrosion, and
ollor faclors llal couId affocl llo inlogrily of llo pipo.
5.2 hendestructive xaminatien
Tlo pipo slouId bo nondoslruclivoIy inspoclod lo
dolormino llo vaII llicInoss and condilion. WoIds in
or noar llo froozo pIug aroa slouId bo inspoclod using
radiograplic or uIlrasonic loclniquos.
5.3 vaIuatien
Basod on llis dala, an ovaIualion and dolorminalion
slouId bo mado as lo llo suilabiIily of a froozo in llal
Iocalion. Hovovor, llo condilion of llo pipo is nol an
absoIulo indicalor llal llo pipo viII or viII nol faiI dur-
ing a froozo pIug oporalion.
6 151IhC
6.1 bnknewn FIuid Preperties
A froozo poinl lomporaluro losl slouId bo porformod
on fIuids of quoslionabIo or unInovn froozo poinl or
froozo rango lo vorify llo suilabiIily of llo producl for
a froozo pIug oporalion. Tlis is parlicuIarIy imporlanl
for lydrocarbon mixluros vill varying viscosily or Iigll
onds llal can vaporizo vlon llo dovnslroam sido of
llo pIug is doprossurod. VoIaliIo compononls in llo Iiq-
uid may provonl a succossfuI froozo pIug, and lloir offocl
musl bo ovaIualod.
6.2 Freeze Peint 1est
Tlo froozo poinl lomporaluro losl can bo porformod
vill a smaII froozo jacIol and associalod oquipmonl.
Tlo jacIol can bo mounlod on a slorl fIangod spooI
fiIIod vill a sampIo of llo fIuid and prossurizod lo
1
1
2
limos llo oporaling prossuro. Aflor a froozo pIug is
formod, llo fIango may bo romovod for inspocling and
ovaIualing llo slrongll of llo pIug.
6.3 1emperature Meniter CaIibratien
Tlo lomporaluro monilor slouId bo poriodicaIIy caIi-
bralod. AddilionaIIy, il slouId bo roulinoIy clocIod by
comparison lo ambionl, ico valor, or ollor roforonco
lomporaluro boforo ovory job.
6.4 0xygen Meniter CaIibratien
Tlo oxygon monilor slouIdbo poriodicaIIy caIibralod.
Il slouId bo clocIod by comparison lo almosploric oxy-
gon conlonl boforo ovory job.

ArticIe 3.3
amaged 1hreads in 1apped heIes
1 5CkIP1I0h
1.1 Intreductien
Tlo dosignroquiromonls of oquipmonl sucl as vossoIs,
maclinory, vaIvos, inslrumonls, olc., vloro cIoso cou-
pIing is roquirod bocauso of oporalionaI, oconomic, or
spaco considoralions, oflon diclalo llo uso of lappod
loIos, usuaIIy vill a slud, bul somolimos vill a cap
scrov. Wlon a slud is usod, llo slud is ongagod villin
a driIIod and lappod loIo al ono ond and socurod vill
a nul al llo ollor ond. Tlo llroads in llo lappod loIo
oflon lavo a ligllor fil vill llo slud llan do llo llroads
in llo nul. Tlo ligllor fil usuaIIy is spocifiod, and llo
slud is usuaIIy bollomod in llo lappod loIo, lo faciIilalo
romoving llo nul from llo slud villoul romoving llo
sludfromllo lappod loIo. Tlroads in lappod loIos oflon
aro damagod vlon sluds aro romovod aflor a poriod of
sorvico.
1.2 Metheds eI kepair AIternatives
Tlis ArlicIo is inlondod lo covor llo ropair of damagod
llroads in lappod bIind loIos in sluddod connoclions
by ono of llo foIIoving mollods:
driIIing and lapping llo oxisling slud loIos lo a
Iargor sizo, and ropIacing llo oxisling sizo faslonor vill
ono sizod accordingIy
driIIing and lapping llo oxisling slud loIos lo
a Iargor sizo, for llo purposo of inslaIIing loIicaI-coiI
llroadod insorls
fiIIing llo oxisling slud loIos vill voId molaI,
rodriIIing, and rolapping llo loIos
1.3 kepair Metheds het Cevered
Ollor mollods vlicl may bo considorod for ropair
of damagod llroads, bul vlicl aro nol covorod in llis
ArlicIo, incIudo llo foIIoving:
rolapping llo oxisling slud loIos vill llo samo
sizo lap (aIso roforrod lo as clasing llo llroads)
ropIacomonl of llo compononl conlaining llo
lappod loIos
NOTI: Mosl of llo guidoIinos in llis ArlicIo aro inlondod for
ropair of damagod llroads in lappod bIind loIos, as vouId bo
found in sluddod connoclions. WliIo llis ArlicIo doos nol spocifi-
caIIy oxcIudo appIicalions sucl as loIos llal oxlond compIoloIy
llrougl llo prossuro compononl, llo usor is caulionod llal many
of llo roquiromonls loroin may nol bo appIicabIo or sufficionl lo
covor lloso casos.
78
2 LIMI1A1I0h5
2.2 ketapping xisting heIes
UnIoss visuaI oxaminalion of llo llroads in llo slud
loIo indicalos subslanliaI damago lo llo llroads, il is
somolimos advanlagoous lo allompl lo rolap llo loIos
using llo samo sizo lap, a procoss Inovn as clasing
llo llroads. Somolimos llo onIy probIom is llal corro-
sion producls and/or rosiduo from llo procoss pIuggod
llo llroads.
2.3 esign Adequacy eI nIarging 5tud heIes
InIargomonl of oxisling slud loIos slaII nol bo dono
unliI an onginooring anaIysis confirms llo dosign ado-
quacy of llo proposod assombIy (soo soclion 3).
2.4 kepair eI Cracks
If an oxaminalion of llo slud loIos rovoaIs cracIs al
llo faco of llo loIo oponing (soo soclion 5), lloso cracIs
slaII bo ropairod prior lo onIargomonl of oxisling slud
loIos, if llo onIargod loIo sizo is nol sufficionl lo romovo
llo cracIs.
If ropairs invoIvo voIding, vill or villoul poslvoId
loal lroalmonl, llo polonliaI oxisls for varpago of llo
assombIy and possibIo IoaIago. Ior somo maloriaIs (sucl
as Iov aIIoy slooIs), subsoquonl poslvoId loal lroalmonl
oporalions may advorsoIy affocl llo maloriaI louglnoss.
AIso, considoralion slaII bo givon lo llo polonliaI for
cracIing of maloriaIs llal may lavo oxporioncod lompor
ombrillIomonl. In lloso silualions, oillor a voIding or
maloriaIs spociaIisl, or boll, slouId bo consuIlod prior
lo commoncing ropairs.
2.6 heIicaI CeiI 1hread Inserts
HoIicaI coiI llroad insorls aro gonoraIIy avaiIabIo up
lo 1
1
2
Unifiod Coarso Sorios (UNC). Tlo appIicalion of
loIicaI-coiI llroadod insorls slaII bo por llo manufaclur-
ors rocommondalions, parlicuIarIy vill rospocl lo sor-
vico condilions (inlornaI, oxlornaI), maloriaIs, and
Ioadings. ASMI B18.29.1 providos addilionaI
informalion.

3 5ICh
3.1 AppIicabIe Cedes
Upon compIolion of llo ropair, llo dosign of llo boIlod
assombIy slaII bo in accordanco vill llo originaI codo
of conslruclion or appIicabIo posl-conslruclion codo.
3.2 1hread MediIicatien
A slandard lapor lap viII produco incompIolo lappod
llroads noar llo bollom of llo lappod loIo, ovon llo
uso of a bolloming lap viII nol onsuro a compIolo finaI
llroad. As a consoquonco, bolloming a fuIIy llroadod
slud inlo a lappod loIo llal las incompIolo llroads noar
llo bollom damagos llo fuII llroads on llo ond of llo
slud. Tlis aImosl onsuros llal llo fuII llroads in llo
lappod loIo viII bo damagod as llo slud vill damagod
llroads is bacIod oul. A praclico llal las boon usod
succossfuIIy lo provonl llis from occurring is lo romovo
somo of llo llroads from llo sluds and lo incroaso llo
dopll of llo lappod loIos accordingIy. A sIolcl vill
suggoslod dimonsions is providod in Appondix I.
3.3 nIargement eI xisting heIes
Tlo dosign considoralions spocifiod in paras. 3.3.1
llrougl 3.3.4 aro appIicabIo lo ropair of damagod
llroads by onIarging llo lappod loIo diamolor.
3.3.1 Check eI 1hread ngagement. Boforo onIarg-
ing llo lappod loIo diamolor, llo Iongll of llroad
ongagomonl slaII bo roclocIod lo onsuro compIianco
vill llo roquiromonls of llo originaI codo of conslruc-
lion |o.g., UG-43(g) of ASMI BIVC Soclion VIII,
Division 1, AD-740 of ASMI BIVCSoclion VIII, Division
2, or KD-615(b) of ASMI BIVC Soclion VIII, Division
3] or appIicabIo posl-conslruclion codo.
NOTI: If llo parls undor considoralion aro nol govornod by llo
ruIos of llo ASMI Codo, anollor appIicabIo codo of conslruclion,
or appIicabIo posl-conslruclion codo, llo dosign may rofor lo ASMI
B1.1 (Appondix B Tlroad Slrongll Dosign IormuIas).
3.3.2 Check eI FIange 5tresses. If llo faslonor diam-
olor is incroasod, llo fIango slrossos (incIuding llo
unlappod maling fIango/covor) slaII bo roclocIod lo
soo if lloy romain villin accoplabIo IovoIs, givon llo
polonliaI for incroasod Ioads gonoralod by llo Iargor
faslonor diamolor. Tlis slouId incIudo considoralion of
incroasod boIl proIoad duo lo llo Iargor faslonors on
fIango slrossos duo lo boIl up.
3.3.3 1apered 5tuds. In somo appIicalions, il may
bo possibIo lo ropIaco llo oxisling sluds vill a cuslom
laporod slud (soo Iig. 1 for an oxampIo), vloro ono
ond of llo slud rolains ils originaI diamolor vliIo llo
ollor ond is onIargod. Tlis mainlains llo dosign boIl
Ioads consislonl vill llo originaI dosign, avoids llo
nood lo driII Iargor loIos in llo maling fIango/covor,
and pormils llo possibIo rouso of llo nuls.
79
3.4 heIe nIargement ImpIicatiens en esign
Wlon llo oxisling lappod loIo is driIIod lo a Iargor
diamolor, maloriaI is romovod from llo compononl con-
laining llo loIo. Tlo dosign slaII considor llo impIica-
lions associalod vill llis ropair mollod lo onsuro llal
llo romaining maloriaI providos sufficionl slrongll lo
salisfy llo inlondod dosign condilions. Appondix II
offors an oxampIo of a clocI mado lo a sluddod oulIol
connoclion in a prossuro vossoI.
3.5 esign eI heIicaI CeiI 1hread Inserts
HoIicaI-coiI llroadod insorls slaII salisfy llo dosign
roquiromonls of llo originaI codo of conslruclion, or
appIicabIo posl-conslruclion codo, for llo spocifiod Ioad-
ing lo bo appIiod lo llo llroadod connoclion. In gonoraI,
llo dosign is basod on baIancing llo lonsiIo slrongll
of llo slud maloriaI againsl llo sloar slrongll of llo
compononl baso maloriaI. Ior maloriaIs nol Iislod in
llo originaI codo of conslruclion, or appIicabIo posl-
conslruclion codo, primary slrossos slouId nol oxcood
llo Iossor of lvo-llirds of llo minimum spocifiod yioId
slrongll or
1
3.5
of llo minimumspocifiod lonsiIo slrongll
of llo appIicabIo maloriaI.
4 FAkICA1I0h
4.1 heIe epth eI Penetratien
DriIIod loIos lo bo lappod slaII nol oxcood llo maxi-
mum dopll of ponolralion llrougl llo llicInoss of llo
prossuro compononl, as dofinod by llo originaI codo of
conslruclion |o.g., UG-43(d) of ASMI BIVCSoclion VIII,
Division 1 or AD-630 of ASMI BIVC Soclion VIII,
Division 2], or appIicabIo posl-conslruclion codo.
4.2 heIe Preparatien eIere weIding
If llo damagod llroads aro ropairod by fiIIing llo
oxisling slud loIos vill voId molaI, llo loIos slaII bo
froo of dobris and llo oxisling llroads romovod (usuaIIy
dono by driIIing oul) lo onsuro llal llo novvoId doposil
doos nol incIudo llis maloriaI.
4.3 weIding Precedures and uaIiIicatiens
WoIding procoduros, voIdors, or voIding oporalors,
vloro usod, slaII bo quaIifiod in accordanco vill llo
originaI codo of conslruclion or appIicabIo posl-
conslruclion codo.
Any spociaI voIding roquiromonls, incIuding proloal
or poslvoId loal lroalmonl, slaII bo in accordanco vill
llo originaI codo of conslrucl ion, or appIicabIo
posl-conslruclion codo. Bocauso of llo polonliaI for
varpago of llo compononl, a voIding/maloriaIs spociaI-
isl slouId bo consuIlod rogarding procoduros/procossos,
proloal, and poslvoId loal lroalmonl.

Fig. 1 xampIe eI 1apered 5tud

hUTF:
(1) Fcr cther slzes, as needed tc attaln a 3:1 taper.
4.5 FIange keIinishing
If llo gasIol conlacl surfaco las boon varpod as a
rosuIl of voId ropairs or loal lroalmonl, il may roquiro
rofinisling. Soo ArlicIo 3.5.
4.6 InstaIIatien eI heIicaI CeiI 1hread Inserts
Wlon loIicaI-coiI llroadod insorls aro usod, lloy slaII
bo inslaIIod in accordanco vill llo manufacluror s
inslruclions.
4.7 1hread CaIIing and Lubricatien
SpociaI allonlion slouId bo givon lo provonl llroad
gaIIing aflor assombIy. In addilion, Iubricanl slouId bo
appIiod lo llo boIl llroad surfaco in accordanco vill
ASMI ICC-1, soclion 7.
5 XAMIhA1I0h
DriIIod loIos slaII bo visuaIIy oxaminod for vorIman-
slip, cIoanIinoss, and ovidonco of cracIing.
5.2 heed Ier AdditienaI h
Wloro maloriaI dolorioralion or damago is suspoclod,
addilionaI nondoslrucl ivo oxaminalion slaII bo
considorod.
80
5.3 xaminatien Precedures
Ixaminalion procoduros slaII bo in accordanco vill
llo originaI codo of conslruclion or appIicabIo
6 151IhC
Tosling roquiromonls associalod vill modificalion of
llo fIango assombIy slaII bo in accordanco vill llo
7 kFkhC5
ASMI B1.1-2003, Unifiod Incl Scrov Tlroads (UN and
UNR Tlroad Iorm)
ASMI B18.29. 1-1993, HoIicaI CoiI Scrov Tlroad
Insorls Iroo Running and Scrov IocIing (Incl
Sorios), incIuding Irrala issuod Augusl 1995
ASMI BoiIor and Irossuro VossoI Codo, 2007 Idilion:
Irossuro VossoIs, Soclion VIII, Division 2
AIlornalivo RuIos, Soclion VIII, Division 3
AIlornalivo RuIos for Conslruclion of Higl Irossuro
VossoIs
ASMI ICC-12000, GuidoIinos for Irossuro Boundary
BoIlod IIango }oinl AssombIy
(08)

kecemmended etaiI Ier 5tud 1hreads MediIicatien te
Prevent amage te 1hreads in 1apped heIes
Fig. I-1 Inch 1hread 5eries]b.5. Custemary bnits

8
- 11 uhC-2
17
32
11
16
7
16
1
9
16
1
9
16
13
16
3
/
- 10 uhC-2
21
32
3
/
1
2
1
3
/
1
1
8
5
8
15
16
7
8
- 9 uhC-2
/9
6/
13
16
5
8
1
7
8
1
3
16
11
16
1
1 - 8 uhC-2
7
8
7
8
11
16
2
3
16
1
7
16
3
/
1
3
16
1
1
8
- 8 uh-2 1
7
8
13
16
2
5
16
1
9
16
3
/
1
5
16
1
1
/
- 8 uh-2 1
1
8
7
8
15
16
2
7
16
1
11
16
3
/
1
7
16
1
1
2
- 8 uh-2 1
3
8
7
8
1
3
16
2
11
16
1
15
16
3
/
1
11
16
1
3
/
- 8 uh-2 1
5
8
7
8
1
7
16
2
15
16
2
3
16
3
/
1
15
16
2 - 8 uh-2 1
7
8
7
8
1
11
16
3
3
16
2
7
16
3
/
2
3
16
6FhFkAL hUTFS:
(a) The tabulated dlmenslcns satlsfy ASMF Ccde Sectlcn vlll, ulvlslcn 1, para. u6-/3(g) requlrements fcr stud materlals havlng an allcw-
able stress cf 25,000 psl and tapped materlals havlng an allcwable stress cf 20,000 psl at the deslgn temperature fcr the |clnt. Fcr
materlals havlng cther allcwable stresses, these dlmenslcns must be ad|usted acccrdlngly.
(b) Uverall stud length may be determlned by addlng the Thlckness cf the Matlng Flange + hut Felght + 6asket Thlckness + F + Thlckness
cf the Spacer (lf any) +
1
/
ln.
(c) All dlmenslcns ln lnches.
81

Fig. I-2 Inch 1hread 5eries]5I bnits

8
- 11 uhC-2 13 17 11 /0 25 1/ 21
3
/
- 10 uhC-2 17 19 13 // 29 16 2/
7
8
- 9 uhC-2 19 21 16 /8 30 17 25
1 - 8 uhC-2 22 22 17 56 37 19 30
1
1
8
- 8 uh-2 25 22 21 59 /0 19 33
1
1
/
- 8 uh-2 29 22 2/ 62 /3 19 37
1
1
2
- 8 uh-2 35 22 30 68 /9 19 /3
1
3
/
- 8 uh-2 /1 22 37 75 56 19 /9
2 - 8 uh-2 /8 22 /3 81 62 19 56
6FhFkAL hUTFS:
able stress cf 173 MPa and tapped materlals havlng an allcwable stress cf 138 MPa at the deslgn temperature fcr the |clnt. Fcr materl-
als havlng cther allcwable stresses, these dlmenslcns must be ad|usted acccrdlngly.
cf the Spacer (lf any) + 6 mm.
(c) ulmenslcns ln cclumns 8 thrcugh F are ln mllllmeters.
82

Fig. I-3 Metric 1hread 5eries]5I bnits

M1/-2 12 17 10 36 22 1/ 19
M16-2 1/ 17 12 39 25 1/ 22
M20-2.5 17 19 13 /5 29 16 26
M2/-3 21 22 16 55 36 19 29
M27-3 2/ 22 19 58 39 19 32
M30-3 28 22 23 61 /2 19 35
M33-3 31 22 26 63 // 19 38
M36-3 33 22 28 66 /7 19 /1
M39-3 36 22 31 69 50 19 //
M/2-3 39 22 3/ 72 53 19 /7
M/5-3 /2 22 37 75 56 19 50
M/8-3 /5 22 /0 78 59 19 53
6FhFkAL hUTFS:
able stress cf 173 MPa and tapped materlals havlng an allcwable stress cf 138 MPa at the deslgn temperature fcr the |clnt. Fcr materl-
als havlng cther allcwable stresses, these dlmenslcns must be ad|usted acccrdlngly.
cf the Spacer (lf any) + 6 mm.
(c) All dlmenslcns ln mlllmeters.
83
(08)

ArticIe 3.3, Mandatery Appendix II
An IIIustrative xampIe 5hewing an ngineering AnaIysis
Asseciated with nIarging a 1apped heIe
II-1 XAMPL 1
Tlo foIIoving is an iIIuslralivo oxampIo sloving an
onginooring anaIysis associ alod vi ll onIarging a
lappod loIo:
Considor llo sludding oulIol filling as slovn boIov

VISSII DATA:
(1) Dosign prossuro 2160 psig al 840I
(2) SloII SA-387 Gr. D v/347 SS voId ovorIay
(3) Sluds 3 in. 8 UN slud boIl, SA-193-B16 maloriaI
(4) Iorging SA-336-I22 v/347 SS voId ovorIay
(5) AIIovabIo slross of forging 840I,
14,520 psi
(6) AIIovabIo slross of slud boIl 840I,
21,200 psi
NOTI: WliIo romoving llo oxisling 3 in. diamolor sluds, somo
of llo slud loIos voro found lo lavo slrippod llroads. Tlo caIcuIa-
lions llal foIIov aro inlondod lo assoss llo adoquacy of llo dosign
if llo slud loIos aro onIargod lo 3
1
4
in.
II-1.1 hemencIature
lolaI cross-soclionaI aroa roquirod in llo
pIano undor considoralion, in.
2
1
aroa of oxcoss llicInoss in llo vossoI sloII
avaiIabIo for roinforcomonl, in.
2
|soo
UG-37(a) of ASMI BIVC Soclion VIII,
Div. 1]
84
2
aroa of oxcoss llicInoss in llo nozzIo vaII
avaiIabIo for roinforcomonl, in.
2
|soo
Div. 1]
3
aroa avaiIabIo for roinforcomonl vlon llo
nozzIo oxlonds insido llo vossoI vaII, in.
2
|soo UG-37(a) of ASMI BIVC Soclion VIII,
Div. 1]
4
cross-soclionaI aroa of llo slud loIo, in.
4 (3 in.)
cross-soclionaI aroa of a slud loIo associ-
alod vill a 3 in. diamolor slud, in.
4 (3 in.)
cross-soclionaI aroa of a slud loIo associ-
alod vill a 3
1
4
in. diamolor slud, in.
lonsiIo slross aroa, in.

2
minimum llroad sloar aroa for oxlornaI

llroads, in.
3
baso Iongll of llal porlion of nozzIo dofin-
ing llo aroa
3
projocling invard from
innor surfaco of vossoI, in.
finislod diamolor of llo oponing, in. |soo
Div. 1]
1
max. maximum minor diamolor of inlornaI
llroad, in.
2
basic pilcl diamolor, in.
2
min. minimum pilcl diamolor of oxlornaI
llroad for cIass of llroad spocifiod, in.
nominaI diamolor of llo slud, in.

odgo dislanco from conlorIino of slud lo
oulor odgo of llo forging, in.
joinl officioncy of llo nozzIo nocI
j oinl officioncy of llo sloII |soo

1
in
Div. 1]
corroclion faclor llal componsalos for llo
varialion in inlornaI prossuro slrossos on
difforonl pIanos vill rospocl lo llo axis of
a prossuro vossoI |soo UG-37(a) of ASMI
BIVC Soclion VIII, Div. 1]
loigll of fundamonlaI lriangIo,
0.866025, in.
3
loigll of llal porlion of nozzIo dofining
llo aroa
3
projocling invard from innor
surfaco of vossoI, in.
loigll of insido of llal porlion of nozzIo

dofining aroa
2
projocling oulvard from
oulor surfaco of vossoI, in.
(08)
(08)

loigll of oulsido of llal porlion of nozzIo

dofining aroa
2
projocling oulvard from
oulor surfaco of vossoI, in.
insido sploricaI radius for lomisploricaI
load, in.
Iongll of ongagomonl, in.

llroad pilcl (1/numbor of llroads por
incl), in.
dosign prossuro, psi
dogroo of pIano vill llo IongiludinaI axis
of llo vossoI, (soo Iig. UG-37 of ASMI
BIVC Soclion VIII, Div. 1)
Insido radius of llo nozzIo undor considor-

alion, in.
aIIovabIo slross of slud boIl, psi
aIIovabIo slross of forging, psi
aIIovabIo slross of sloII, psi

spocifiod vossoI vaII llicInoss, in. |soo
Div. 1]
roquirod llicInoss of llo sloII, in. |soo

Div. 1]
roquirod llicInoss of a soamIoss nozzIo

vaII, in. |soo UG-37(a) of ASMI BIVC
Soclion VIII, Div. 1]
sum of aroas conlribuling lo roinforco-

monl,
1
+
2
+
3
, in.
II-1.2 vaIuate Length eI ngagement,
Ior UG-43(g) of ASMI BIVC Soclion VIII, Division

1, llo minimum llroad ongagomonl Iongll is llo Iargor
of
(llo nominaI diamolor of llo slud) or

Maximum aIIovabIo slross vaIuo of
0.75
slud maloriaI al dosign lomporaluro

Maximum aIIovabIo slross vaIuo of
lappod maloriaI al dosign lomporaluro
0.75 (3.25)
21,200
14,500
3.564 in.
Sinco llis vaIuo is Iargor llan
(3.25 in.), llo roquirod

Iongll of ongagomonl,
, is 3.564 in.
Sinco acluaI llroad dopll (4
1
2
in.) oxcoods caIcuIalod
, Iongll of ongagomonl is adoqualo.

NOTI: Tlo roquirod Iongll of ongagomonl viII bo clocIod vill
llo criloria in ASMI B1.1-2003, in parl for iIIuslralivo purposos,
bul aIso bocauso somo of llo vaIuos for diamolors viII bo usod
furllor in llo anaIysis.
II-1.2.1 Length eI ngagement,
, bsing Criteria Frem

Appendix eI A5M 1.1-2003
2 (
)
3.1416
1
max.
1
2
+ 0.57735 (1/) (
2

1
max.)
85
3.1416
2
2
3
16
2
vloro
lonsiIo slross aroa of llroad
minimum llroad sloar aroa for oxlornaI

llroads
1
max. maximum minor diamolor of inlornaI
llroad, in.
2
basic pilcl diamolor
2
min. minimum pilcl diamolor of oxlornaI
llroad for cIass of llroad spocifiod, in.
0.866025404 0.866025404/8 0.1083
minimum Iongll of ongagomonl, in.

(NOTI: ASMI B1.1 dofinos
as )
1/ numbor of llroads por incl
NOTI: Tlo faclor of 2 in llo numoralor of llo abovo formuIa for
moans llal il is assumod llal llo aroa in sloar of llo slud is

lvico llo lonsiIo slross aroa lo dovoIop llo fuII slrongll of llo slud.
Tlis vaIuo is sIigllIy Iargor llan roquirod and providos a smaII
faclor of safoly againsl slripping.
Ior a 3
1
4
in. 8 UN Slud BoIl
CIass 2 Iil CIass 3 Iil Commonls
1
max. 3.140 3.1297 Irom TabIo 3A of
ASMI B1.1
2
min. 3.1575 3.1623 Irom TabIo 3A of
ASMI B1.1
2
3.1688 3.1688 Irom TabIo 13 of
ASMI B1.1
Ior a CIass 2 fil
3.1416
3.1688
2
3 (0.1083)
16
2
8.0898 in.
2
Subslilulo llo vaIuo of
(lonsiIo slross aroa) for llo

vaIuo of
(minimum llroad sloar aroa of inlornaI

llroads) and soIvo for llo llroad ongagomonl,
2 8.0898
3.1416 3.140
1
2
+ 0.57735
2.823 in.
Ior a CIass 3 fil
3.1416
3.1688
2
3 (0.1083)
16
2
8.0898 in.
2
2 8.0898
3.1416 3.1297
1
2
+ 0.57735
2.529 in.
Sinco acluaI llroad dopll (4
1
2
in.) oxcoods caIcuIalod
, Iongll of ongagomonl is adoqualo for oillor a CIass

2 or 3 fil.

ClocI dislanco roquirod from llo odgo of llo nozzIo

forging lo llo conlorIino of llo slud boIl
Iorco gonoralod by slud boIl
Maximum AIIovod Iorco on Iorging

4
(2)
2
Assuming llo nov slud diamolor of 3

1
4
in., sol llo
forco llo maximum aIIovod forco on llo forging and
soIvo for llo minimum odgo dislanco
4
(2)
2
21,200 8.0898
4
(2)
2 2
14,520
2.523 in.
Tlo acluaI odgo dislanco of 3 in. oxcoods llo roquirod
minimum odgo dislanco, .
NOTI: InIargomonl of llo oxisling 3 in. 8 UN Slud BoIl lo a 3
1
4
in. 8 UN Slud BoIl appoars lo bo oIay, lovovor, nozzIo oponing
roinforcomonl slouId bo vorifiod.
II-1.3 hezzIe keinIercement CaIcuIatien. Minimum
llicInoss of lomisploricaI load,
2160 61.1875
(2 14,520 2160)
4.62 in.
Minimum llicInoss of nozzIo nocI,
2160 12.1875
(14,520 2160)
1.99 in.
Roquirod roinforcomonl aroa,
0.5
0.5 24.375 4.62 1.0 56.305 in.

2
86
AvaiIabIo roinforcomonl
1
0.5 (
) 0.5 0.061 in.

2
1
2
(
) (
1
2
(10.75 + 8.8577) 61.985 in.
2
1
2

3

3
1
2
2.2114 8.9375 9.8822 in.
2

1
+
2
+
3
0.061 + 61.985 + 9.8822 71.928 in.
2
Sublracl slud loIo aroa from
:
Ior a 3 in. Slud BoIl:
4
(
Slud Dopll) +
1
2

/2 lan 59)
(3 4.5) +
1
2
3 0.901 14.852 in.
2
Tloroforo, avaiIabIo roinforcomonl

4
57.076 in.
2

Ior a 3
1
4
in. Slud BoIl:
4
(
Slud Dopll) +
1
2

/2 lan 59)
(3.25 4.5) +
1
2
3.25 0.976 16.211 in.
2

4
55.72 in.
2

NOTI: If vo considor on a givon pIano llrougl llo nozzIo conlor-
Iino llal onIy ono slud loIo is onIargod lo 3
1
4
in. vliIo mainlaining
llo opposilo loIo diamolor al 3 in. vo may bo abIo lo caIcuIalo llo
roinforcomonl as foIIovs:
Roquirod Roinforcomonl, 2 56.305 112.61 in.
2
2
4 (3 in.)

4 (3 in.)
2 113.03 112.61
II-2 XAMPL 2
IxampIo 1 in soclion I-1 is for a conlraIIy Iocalod
oponing in a sploricaI sloII. IxampIo 2 las boon modi-
fiod for an oponing in a cyIindricaI sloII, lo iIIuslralo
llo difforonco associalod vill sluds llal slraddIo llo
naluraI conlorIinos sucl llal llo roquirod aroa for llo
noarosl pair of lappod loIos vouId bo in a pIano of
roducod roquirod roinforcomonl aroa. OnIy llo roinforco-
monl caIcuIalion is ropoalod loro, llo procoding caIcuIa-
lions invoIving Iongll of Ingagomonl and Idgo
Dislanco romain vaIid.

NOTI: InIargomonl of llo oxisling 3 in. 8 UN Slud BoIl lo a
3
1
4
in. 8 UN Slud BoIl appoars lo bo oIay, lovovor, nozzIo oponing
roinforcomonl slouId bo vorifiod.
II-2.1 hezzIe keinIercement CaIcuIatien
II-2.1.1 Minimum 1hickness eI CyIindricaI 5heII,
.
Ior llo purposos of llis iIIuslralivo oxampIo, llo mini-
mum llicInoss of llo cyIindricaI sloII,
, viII bo
assumod lo bo llo samo as llal for llo sploricaI sloII
(4.62 in.).
II-2.1.2 Minimum 1hickness eI hezzIe heck,
2160 12.1875
(14,520 2160)
1.99 in.
Tlo nozzIo in llis oxampIo viII bo inslaIIod in llo
cyIindricaI sloII sucl llal llo sluds viII slraddIo llo
naluraI conlorIinos of llo vossoI. Tlo roinforcomonl aroa
viII bo clocIod in llo pIano conlaining llo loIo cIososl
lo llo IongiludinaI axis of llo vossoI.

Tlo forging conlains 16 sluds, llus llo angIo dofinod
by adjaconl sluds is: 360 16 22.5 dog.
87
Sinco llo slud loIos slraddIo llo naluraI conlorIinos
of llo vossoI, llo angIo from llo IongiludinaI conlorIino
lo llo adjaconl slud loIo is: 22.5 2 11.25 dog.
Irom Iig. UG-37 of ASMI BIVC Soclion VIII,
Division 1 for angIo of 11.25 dog, 0.98.
Roquirod Roinforcomonl Aroa,
0.5
0.5 24.375 4.62 0.98 55.181 in.

2
AvaiIabIo roinforcomonl
1
0.5 (
) 0.5 0.061 in.

2
1
2
(
)(
1
2
(10.75 + 8.8577) 61.985 in.
2
1
2

3
l
3
1
2
2.2114 8.9375 9.8822 in.
2

1
+
2
+
3
0.061 + 61.985 + 9.8822 71.928 in.
2
Sublracl slud loIo aroa from
:
Ior a 3 in. Slud BoIl
4
(
Slud Dopll) +
1
2

/2 lan 59)
(3 4.5) +
1
2
3 0.901 14.852 in.
2

4
57.076 in.
2

Ior a 3
1
4
in. Slud BoIl
4
(
Slud Dopll) +
1
2

/2 lan 59)
(3.25 4.5) +
1
2
3.25 0.976 16.211 in.
2
55.72 in.
2


ArticIe 3.4
FIaw xcavatien and weId kepair
1 5CkIP1I0h
Surfaco fIavs |Iig. 1, iIIuslralion (a)] or omboddod
fIavs |Iig. 2, iIIuslralion (a)] in baso maloriaI or voIds
llal oxcood llo aIIovancos of llo appIicabIo codo of
conslruclion or posl-conslruclion codo can bo romovod
by oxcavalion |Iig. 1, iIIuslralion (b) and Iig. 2, iIIuslra-
lion (b)]. Tlo romaining cavily can bo fiIIod vill voId
fiIIor molaI |Iig. 1, iIIuslralion (c) and Iig. 2, iIIuslralion
(c)], or Iofl as is, undor condilions doscribod in llis
ArlicIo. Doponding on llo lypo and Iocalion of llo fIav,
and llo lypo of baso molaI or voId maloriaI, oxcavalion
can bo accompIislod by moclanicaI romovaI mollods
(grinding, maclining, Iapping, loning, or fIapping), or
by llormaI romovaI mollods (llormaI gouging).
Doscriplions of lloso oxcavalion loclniquos aro pro-
vidod in Mandalory Appondix I.
2 LIMI1A1I0h5
2.2 Crinding
2.2.1 Grinding vlooIs slaII nol bo forcod or ovor-
Ioadod, in ordor lo avoid llo safoly lazards from vlooI
faiIuro. Iurllormoro, ovorIoading llo grinding vlooI
can causo aroas of IocaIizod ligl lomporaluro in llo
subslralo boing ground, Ioading in somo casos lo llo
formalion of brillIo unlomporod marlonsilo, or ligll,
slaIIov surfaco cracIs. Abusivo grinding and unovon
and rougl finisl can rosuIl in roducod faliguo slrongll
or promaluro faiIuro duo lo llo inlroduclion of Iargo
surfaco rosiduaI lonsiIo slrossos and slross risors. Tloso
probIoms normaIIy can bo avoidod by using Iigllor
grinding praclicos llal avoid surfaco oxidalion, ovidonl
llrougl discoIoralion. Il may bo nocossary lo proloal
somo ligl slrongll aIIoy slooIs prior lo grinding. Grind-
ing vlooIs aro manufaclurod lo bo usod on spocific
maloriaIs (forrilic or auslonilic slooIs, masonry, olc.).
Tloroforo, onIy grinding vlooIs spocificaIIy dosignod
lo vorI on llo maloriaI boing ground slaII bo usod.
Rolary fiIos slouId bo considorod for nicIoI aIIoys.
2.2.2 Grinding or culling consumabIos usod on
carbon or Iov aIIoy slooI maloriaIs viII bocomo improg-
nalod vill rosiduos of lloso maloriaIs and bocomo
88
unsuilabIo for uso vill auslonilic slainIoss slooIs. Abra-
sivo culling or grinding consumabIos slouId bo sogro-
galod for uso on carbon and Iov aIIoy slooIs from lloso
usodfor auslonilic slainIoss slooI subslralos. Surfaco con-
laminalion of auslonilic slainIoss slooI vill carbon or
Iov aIIoy slooI rosiduos can rosuIl in surfaco corrosion
or pilling of llo auslonilic slainIoss slooI. To avoid sucl
probIoms, onIy grinding vlooIs dosignalod as auslonilic
slainIoss slooI grinding vlooIs slaII bo usod on lloso
maloriaIs.
2.2.3 Wlon grinding oul slross corrosion cracIs
in slainIoss slooI, or in llo caso of slooIs llal lavo sufforod
from anodic slross corrosion cracIing (sucl as amino or
causlic slross corrosion cracIing), il is nocossary lo quaI-
ify and conlroI llo amounl of loal gonoralod lo avoid
maIing llo cracIs doopor and Iongor as a rosuIl of oxcos-
sivo loal. SlooI conlaminalod vill causlic or aminos can
aIso rocracI during voIding ropairs or llormaI culling.
Approprialo cIoaning procoduros slaII bo usod prior lo
oxcavalion or ropair.
2.2.4 In ligll spacos, burring looIs may bo usod
in pIaco of grinding vlooIs.
2.3 Machining
Wlon culling fIuids aro usod, caro slaII bo laIon lo
provonl lloir conlacl on surfacos vloro lloy may bo
dolrimonlaI. Iurllormoro, clips of llo maclinod molaI
slaII bo conlroIIod and Iopl from onloring compononls
vloro lloir prosonco can bo dolrimonlaI.
2.4 hening
Tlo loning spoods slaII bo adjuslod as a funclion of
Iongll-lo-boro ralio of llo compononl and ils maloriaI
lardnoss.
2.5 FIapping
2.5.1 IIapping slouId onIy bo usod lo smooll or
poIisl a surfaco. IIapping is unsuilabIo for romoving
dofocls ollor llan suporficiaI surfaco bIomislos.
2.5.2 Tlo abrasivo marIs of llo fIappor slouId bo
diroclod porpondicuIar lo llo diroclion of llo procoding
pass. MarIs of llo procoding pass slouId bo romovod
prior lo procooding lo llo noxl finor gril. In llis vay,
dislorlion of llo surfaco viII bo minimizod and smooll
surfacos can bo oblainod.

Fig. 1 xcavatien and weId kepair eI 5urIace FIaw
6FhFkAL hUTF: A 3-tc-1 taper ls nct requlred when the cavlty wlll
be fllled wlth weld metal.
Fig. 2 xcavatien and weId kepair eI
mbedded FIaw
6FhFkAL hUTF: A 3-tc-1 taper ls nct requlred when the cavlty wlll
be fllled wlth weld metal.
89
2.6 1hermaI Ceuging
2.6.1 Wlon llormaI gouging by carbon arc or
pIasma arc, llo vory rapid loaling lo moIlon lompora-
luros and subsoquonl quoncling lo ambionl lomporaluro
can rosuIl in lardonod or brillIo loal-affoclod zonos.
Tlis llormaIIy affoclod maloriaI slouId bo subsoquonlIy
romovod by a moclanicaI procoss, sucl as grinding.
2.6.2 Ior somo maloriaIs il may bo nocossary lo
proloal llo molaI prior lo arc gouging in ordor lo provonl
cracIing, in parlicuIar maloriaIs llal aro roquirod lo bo
poslvoId loal lroalod by llo codo of conslruclion or
2.7 CeneraIized amage
Tlis ropair loclniquo appIios voII lo IocaI dofocls.
Wloro damago is oxlonsivo, sucl as gonoraI slross corro-
sion cracIing of slainIoss slooI, ropIacomonl slouId bo
considorod.
3 5ICh
3.1 xcavatien witheut weId epesit
MaloriaI or voId fIavs opon lo llo surfaco |Iig. 1,
iIIuslralion (a)] or omboddod fIavs |Iig. 2, iIIuslralion
(a)] aro lypicaIIy romovod by a moclanicaI (abrasivo)
mollod (Iig. 3). If llo romaining vaII llicInoss of llo
oxcavalion, vill aIIovanco for fuluro corrosion, is
groalor llan llo minimum roquirod vaII llicInoss
roquirod by llo appIicabIo codo of conslruclion or
posl-conslruclion codo, sucl as llo IocaI llin aroa ruIos
of AII RI 579/ASMI IIS-1, llon llo oxcavalod aroa
may bo bIondod lo a 3:1 or smoollor profiIo sIopo, and
Iofl as-is for rolurn lo sorvico.
3.2 weId epesitien
Wlon llo romovaI of a fIav producos a romaining
vaII llicInoss boIov llo Iimil pormillod by llo appIica-
bIo codo of conslruclion or posl-conslruclion codo,
incIuding aIIovanco for fuluro corrosion, llon llo cavily
slaII bo ropairod by doposilion of voId molaI |Iig. 1,
iIIuslralion (c) and Iig. 2, iIIuslralion (c)] or anaIyzod
for filnoss-for-sorvico. Wlon llo dopll of maloriaI oxca-
valod nocossilalos a voId ropair, llo cavily slaII bo pro-
parod for voIding. Iillor during or foIIoving dofocl
romovaI, llo oxcavalion slaII bo slapod lo provido ado-
qualo accoss for llo voIding oporalion in ordor lo faciIi-
lalo propor fusion, and avoid sIag onlrapmonl, or IacI
of ponolralion. To minimizo voId slrinIago slrossos, llo
vidll of llo cavily slouId onIy bo as vido as noodod
lo onsuro dofocl romovaI and lo faciIilalo voIding as
proviousIy doscribod.
3.3 MechanicaI xcavatien
If llo oxcavalion is porformod using a llormaI romovaI
procoss (carbon arc or pIasma arc gouging), an addi-
lionaI 1.5 mm (
1
16
in.) of maloriaI slaII bo romovod by

Fig. 3 Crinding eI weId FIaw
a moclanicaI romovaI procoss sucl as grinding, prior lo
llo finaI inspoclion and boforo voIding bogins. Tlis is
nocossary lo romovo any surfaco cracIs, lardonod malo-
riaI, scaIo, or carbon doposil.
4 FAkICA1I0h
4.1 kepair 5teps
Tlo roquiromonls spocifiod in paras. 4.1.1 llrougl
4.1.5 aro gonoraIIy foIIovod lo oxcavalo a fIav.
4.1.1 Iocalo and oxposo llo fIav. Claraclorizo llo
fIav (sizo, dopll, orionlalion) lo llo oxlonl possibIo. If
llo fIav is a cracI, llo cracI lips may bo roundod by
driIIing lo procIudo cracI from propagaling during ils
oxcavalion.
4.1.2 Romovo llo fIav by grinding, maclining,
loning, or llormaI gouging. In soIocling and appIying
a romovaI procoss, rofor lo llo guidanco in paras. 2 and
3 of llis ArlicIo.
4.1.3 Vorify dofocl romovaI by inspocling llo cavily
using visuaI oxaminalion (VT) and Iiquid ponolranl losl-
ing (IT), magnolic parlicIo losling (MT), or oddy curronl
losling (IT) as approprialo. Moasuro llo romaining vaII
llicInoss of llo oxcavalod cavily using an approvod
llicInoss moasuromonl loclniquo. If l-romaining is
groalor llan llo minimum roquirod llicInoss as dolor-
minod by a filnoss-for-sorvico ovaIualion, llo oxcavalion
90
cavily nood nol bo fiIIod vill voId doposil, as providod
in para. 3.1.
4.1.4 Wlon roquirod by dosign (para. 3), ropair
llo cavily by voIding according lo a quaIifiod voIding
procoduro spocificalion (WIS), using a quaIifiod voIdor,
as roquirod by llo appIicabIo codo of conslruclion or
4.1.5 Iorform proloal or poslvoId loal lroalmonl,
vlon roquirod by llo appIicabIo codo of conslruclion
or posl-conslruclion codo, as indicalod by ovnor-usor
spocificalion, or as diclalod by sorvico condilions.
4.2 5peciaI Fixtures
In somo casos, spociaI fixluros may bo roquirod lo
accompIisl procisionvorI. In addilion, il is oflon bonofi-
ciaI lo dovoIop spociaI gagos lo monilor llo dopll of
molaI romovaI and lo provonl oxcossivo maloriaI from
boing romovod. SpociaI conlour lompIalos or common
carponlor gagos may bo usod and may bo inlogralod
inlo spociaI fixluros.
5 XAMIhA1I0h
5.1 CriticaI 5ervice
In crilicaI sorvico appIicalions, foIIoving a IocaI ropair,
llo finaI surfaco and adjaconl aroa slaII bo oxaminod
using VT and IT, MT, or IT, in accordanco vill llo

dofocl accoplanco criloria of llo appIicabIo codo of con-
5.2 veIumetric xaminatien
VoIumolric oxaminalion (RT or UT) slaII bo consid-
orod vloro lloro is a possibiIily of fIavs inlroducod
during ropair voIding, sucl as slrinIago cracIs from
doop voId ropairs in llicI soclions.
5.3 AdditienaI xaminatiens
AddilionaI oxaminalions slaII bo porformod if
roquirod for simiIar voIds by llo appIicabIo codo of
6 151IhC
6.1 AppIicabiIity
GonoraIIy, and unIoss spocifiod ollorviso in llo appIi-
cabIo codo of conslruclion or posl-conslruclion codo,
voId ropairs llal lavo fuIIy ponolralod llo compononl
vaII slouId bo subjoclod lo oillor IoaI losling or voIu-
molric oxaminalion, or boll, foIIoving llo ropair and
any poslvoId loal lroalmonl lo vorify llo inlogrily of
llo ropair.
91
6.2 1est Methed
If a IoaI losl is porformod, il may bo lydroslalic,
pnoumalic, sonsilivo IoaI, or in-sorvico as roquirod by
llo appIicabIo codo of conslrucl ion or posl-
conslruclion codo.
6.3 xemptien
Wlon llo oxcavalion doos nol fuIIy ponolralo llo com-
pononl prossuro boundary, IoaI losling may bo vaivod.
7 kFkhC5
ANSI B7.1, Safoly Roquiromonls for llo Uso, Caro and
Iroloclion of Abrasivo WlooIs
ANSI B74.2, Spocificalions for Slapos and Sizos of
Grinding WlooIs, and for Slapos, Sizos and
Idonlificalion of Mounlod WlooIs
ANSI B74.13, MarIings for Idonlifying Grinding WlooIs
and Ollor Bondod Abrasivos
Slrool, NW, Waslinglon DC 20005-4070

MetaI kemevaI Precess
I-1 FLAPPIhC
IIapping is a molaI romovaI procoss invoIving a rolal-
ing looI fabricalod of abrasivo papors. IIappor vlooIs
como in a varioly of gril sizos and slouId bo vorIod
from llo moro coarso gril lo llo finor gril.
I-2 CkIhIhC
Grinding is llo procoss of abrading llo surfaco of
a maloriaI for llo purposo of romoving porlions of llo
maloriaI. Tlo procoss is usod lo romovo IocaIizod cracIs,
pils, doposils, lardonod surfacos, olc. Iquipmonl usod
for grinding incIudos ponciI or smaII disc grindors lo
romovo IocaI dofocls, and Iargo disc or vlooI grindors
lo romovo Iargor dofocls. Tlo grinding oquipmonl can
bo oIoclric or air-drivon, vill vlooIs of various slapos,
sizos, and abrasivo claraclorislics.
Ivory grinding vlooI las lvo consliluonls: llo
abrasivo llal doos llo culling and llo bond llal loIds
llo abrasivo compononl. Varialions of lloso compononls
can bo soIoclod lo givo a vido rango of grinding clarac-
lorislics. Tlo llroo Amorican NalionaI Slandards
Inslilulo (ANSI) slandards llal provido spocificalions
for grinding vlooIs aro as foIIovs:
ANSI B74.13, MarIings for Idonlifying Grinding
WlooIs and Ollor Bondod Abrasivos
ANSI B74.2, Spocificalions for Slapos and Sizos
of Grinding WlooIs, and Slapos, Sizos, and
Idonlificalion of Mounlod WlooIs
ANSI B7.1, Safoly Roquiromonls of llo Uso,
Caro, and Iroloclion of Abrasivo WlooIs
ManuaI grinding is gonoraIIy dividod inlo ono of
llroo calogorios:
Rougl grinding roIalivoIy rapid romovaI of
oxcoss voId molaI or baso maloriaI using coarso
abrasivos.
IoIisling and bIonding aclioving a somi-
smooll finisl, using modium abrasivos.
Buffing aclioving a Iuslrous and rofIoclivo
finisl, using fino abrasivos usuaIIy in a paslo or Iiquid
volicIo.
I-3 h0hIhC
Honing is anabrasivo procoss llal is usodlo oblain
a fino finisl on llo insido surfaco of a cyIindricaI
compononl.
92
Honing looIs aro pIacod in llo boro of llo compo-
nonl and a radiaI Ioad is appIiod sucl llal llo loning
slonos aro in conlacl vill llo boro surfaco. Tlo lono
is llon rolalod in llo boro, gonoraling a ligl-quaIily
surfaco.
Honing slonos gonoraIIy aro manufaclurod of aIu-
minum oxido, siIicon carbido, or diamond abrasivo grils,
loId logollor by vilrifiod cIay, rosin, or a molaI bond.
Tlo grain and grado of abrasivo lo bo usod is basod on
llo amounl of slocI lo bo romovod and llo surfaco finisl
dosirod. SiIicon carbido is gonoraIIy usod for casl iron,
vliIo aIuminum oxido is gonoraIIy usod on slooI. As
vill grinding discs and Iapping compound, llo finor
llo gril, llo finor llo surfaco finisl.
I-4 LAPPIhC
Iapping is a poIisling loclniquo llal can bo usod
lo proparo surfacos roquiring a vory smooll finisl. Iap-
ping is nol oconomicaI for romoving doop dofocls. A
gonoraI ruIo of llumb is llal Iapping mollods aro suil-
abIo for slaIIov dofocls Ioss llan 0.05 mm (0.002 in.).
Dofocls Iocalod groalor llan llis dopll slouId bo
romovod by ollor mollods.
Iapping maclinos aro avaiIabIo as porlabIo or
boncl-lypo sysloms. In many casos, Iapping is por-
formod vill spociaI discs or pIalos mado spocificaIIy for
a givon lypo of appIicalion. Tloso pIalos aro normaIIy
vory llicI lo mainlain dimonsionaI slabiIily. Aflor dofocl
romovaI, llo surfaco slouId bo Iappod lo llo finisl and
dimonsions spocifiod by llo dosign.
I-5 MAChIhIhC
Maclining using porlabIo oquipmonl can provido
for dofocl romovaI and voId proparalion in a singIo slop.
Maclining vill moclanizod culling oquipmonl is usod
lo romovo dofocls vill procision. Maclining oquipmonl
usod lo romovo dofocls or proparo a surfaco for ropair
incIudo boring bars, miIIing maclinos, magnolic driIIs,
fIango facors (porlabIo Iallos), and pipo culling and bov-
oIing maclinos. Maclining las llo advanlago of culling
and forming llo voId proparalion vill a singIo pioco
of oquipmonl vliIo cIosoIy conlroIIing dimonsionaI
loIorancos.
IorlabIo boring bars lavo boon usod vloro cir-
cumforonliaI maclining of a boro is roquirod, sucl as in
vaIvo mainlonanco. Ollor bars aro avaiIabIo vill accos-
sorios lo grind or miII uniquo goomolrios, and lo driII
and lap slud loIos.

Fig. I-1 eat 5ampIe
IorlabIo miIIing maclinos can bo usod lo romovo
IocaIizod maloriaIs al a faslor ralo llan maclinos
mounlod on llo compononl oulor or innor diamolors.
SmaII miIIing maclinos lavo boon dovoIopod lo oporalo
in roIalivoIy roslriclod Iocalions.
Maclining gonoraIIy invoIvos llo uso of culling
fIuids llal porform sovoraI funclions incIuding Iubrica-
lion, cooIing, and clip romovaI.
I-6 1hkMAL C0bCIhC
In silualions vloro dofocls aro found lo bo oxlon-
sivo and vloro accuracy is nol crilicaI, llormaI gouging
(carbon arc gouging or pIasma arc gouging) can bo usod
offoclivoIy.
TlormaI gouging loclniquos aro llormaI romovaI
procossos llal invoIvo IocaIizod moIling of llo molaI,
vlicl is quicIIy svopl avay by llo forco of ligl voIocily
air or gas jols.
I-7 0A1 5AMPL Cb11IhC
Boal sampIos aro molaI sampIos in llo slapo of a
boal luII llal aro cul oul from baso molaI, voIdmonls,
or voId loal-affoclod zonos (Iig. I-1). Tlo procoss can bo
usod for romovaI of voId dofocls, bul is moro commonIy
usod for oblaining sampIos of baso maloriaIs or voIds
for molaIIurgicaI or moclanicaI losling.
, somolimos roforrod lo as
or , aro moclanicaI dovicos
dosignod lo romovo a porlion of a voId or molaI pIalo
by sav culling from llo pIalo surfaco. Tlo maclino is
a sav vill a dislod slapo bIado, capabIo of oxcavaling
and romoving a boal-slapod spocimon from a fIal sur-
faco in any posilion.
Boal sampIo cullors can bo air povorod or oIoclric
molor drivon. Tloy aro porlabIo dovicos llal aro oasiIy
93
mounlod on llo surfaco of llo maloriaI lo bo oxcavalod
by moans of four ancloring boIls voIdod lo llo surfaco.
Slim spacors aro usod lo adjusl llo vidll and dopll of
cul by conlroIIing llo spaco bolvoon llo sav mounling
framo and llo surfaco of llo pIalo.
Onco socuroIy mounlod on llo anclor boIls, llo
culling procoss bogins by maIing a singIo cul al llo
odgo of llo maloriaI lo bo oxcavalod. Tlo curvod bIado
is fodinlo llo maloriaI unliI llo dosirod dopll is acliovod
and llo sav circumforonco is al rigll angIos lo llo joinl.
Tlo bIado is llon rolraclod, llo sav rolalod 180 dog and
a socond cul is mado. Tlo lvo culs mool aulomalicaIIy
in llo samo pIano and llo oxcavalion is compIolo.
Boal sampIos can bo cul oillor IongiludinaI or
lransvorso vill rospocl lo llo voId joinl. Tloy aro boal
slapod and llo cul sidos lavo a sploricaI curvaluro. Tlo
sizo varios in proporlion lo llo llicInoss of llo pIalo
boing cul, lovovor, spocimons can rango from a smaII
sizo of
1
8
in. dopll 2
3
8
in. Iongll
3
8
in. vidll lo a
Iargo sizo of 1 in. dopll 4
3
4
in. Iongll 1
1
2
in. vidll.
Iargor spocimons can bo oxcavalod vill spociaIIy
dosignod oquipmonl.
Tlo oxcavalod boal sampIos aro Iargo onougl lo
aIIov for various moclanicaI losling procossos. Cross
soclions of llo boals can bo usod for lardnoss losling
or molaIIograplic inspoclion. IuII-Iongll spocimons can
bo maclinod for lonsiIo losling, bond losling, or Clarpy
V-nolcl impacl losling.
Onco llo boal sampIo las boon romovod, llo cullor
can bo dolaclod from ils mounlod posilion and llo
anclor boIls can bo romovod from llo pIalo surfaco. Tlo
cavily Iofl by llo romovaI of llo oxcavalod boal sampIo
is vory conducivo lo ropair voIding. Tlo laporod naluro
of llo cavily onds and llo sIoping curvaluro of llo cavily
vaIIs aIIov compIolo and oasy accoss for mosl voIding
procossos.
(08)

ArticIe 3.5
FIange kepair and Cenversien
1 5CkIP1I0h
1.1 Intreductien
Tlis ArlicIo appIios lo llo rofinisling of fIango facos
lo ropair moclanicaI imporfoclions or damago from cor-
rosion or ollor damago in sorvico, or lo clanging llo
fIango faco finisl lo onabIo llo uso of a difforonl gasIol.
Tlo surfaco finisl of a fIango conlacl surfaco is ossonliaI
lo llo IoaI ligllnoss of llo gasIolod joinl. Wlon surfaco
finisl dolorioralos in sorvico, il can bocomo nocossary
lo oillor ropIaco llo fIango or rofinisl llo fIango faco.
1.2 werk Lecatien
Tlo ropair can bo porformod in silu using a porlabIo
maclino looI, or llo pipo soclion or oquipmonl con-
laining llo damagodfIango can bo romovod and ropairod
in llo slop.
2 LIMI1A1I0h5
2.2 kecurrence eI amage
IIango rofinisling viII rosloro llo fIango facing bul
may nol oIiminalo llo causo of llo iniliaI imporfoclion
or damago. Tloroforo, llo imporfoclion or damago may
rocur. Considoralion slaII bo givon lo llo possibIo rocur-
ronco of llo originaI imporfoclion/damago moclanism.
2.3 kemaining 1hickness
Tlo fIango may nol bo sufficionlIy llicI lo pormil
molaI romovaI by maclining andsliII mool llo minimum
llicInoss roquirod for llo dosign prossuro raling. In sucl
a caso, il viII bo nocossary lo incroaso llo fIango ring
llicInoss by voId molaI buiIdup boforo romaclining llo
surfaco. As an aIlornalivo soIulion, a spIil ring fIango
may bo addod lo llo bacI of llo oxisling fIango lo com-
ponsalo for roducod fIango ring llicInoss, vloro goomo-
lry and spacing pormils, and as quaIifiod by llo
approprialo dosign caIcuIalions.
2.4 kesiduaI 5tress
Tlo maclining of voId ovorIayod or voId buiIl-up
surfacos llal lavo nol boon slross-roIiovod may causo
llo rodislribulion of rosiduaI slrossos and subsoquonl
94
dimonsionaI dislorlion ovor limo. In sucl inslancos, pro-
caulions sucl as porforming a slross-roIioving loal lroal-
monl prior lo finisl maclining slaII bo considorod lo
onsuro finaI dimonsionaI slabiIily.
3 5ICh
3.1 kaised Face
Undor-llicInoss of a raisod faco duo lo rofinisling
slaII bo accoplabIo, providod llo minimum finislod
loigll of llo raisod faco is 0.8 mm (0.031 in.).
3.2 1hickness vaIuatien
If fIango rofinisling nocossilalos romovaI of maloriaI
from ollor llan llo raisod faco sucl llal llo fIango
dimonsions no Iongor compIy vill llo originaI dosign
dimonsions minus llo originaI corrosion aIIovanco or
llo roquiromonls of an appIicabIo spocificalion or slan-
dard, llo fIango slaII bo ovaIualod lo onsuro llal llo
romovaI of maloriaI doos nol compromiso dosign inlog-
rily. Dosign ovaIualion mollods of an appIicabIo nov
conslruclion codo (sucl as ASMI BIVC Soclion VIII,
Division 1, Appondix 2), or an appIicabIo
posl-conslruclion codo or slandard, slaII bo usod.
3.3 Finish and FIatness
Tlo gasIol soaling roquiromonls in lorms of fIango
surfaco finisl and fIalnoss slaII bo considorod.
3.3.1 FIatness. Ior oxampIo, AII 660 and TIMA
pormil dovialions from fIalnoss llal oxcood lloso llal
aro rocommondod for corlain gasIol lypos of maloriaIs
(o.g., fIal molaI). Ior guidanco on fIango faco fIalnoss
loIoranco, rofor lo Appondix D of ASMI ICC-1.
3.3.2 Finish. Soo TIMA Iig. I-4 for pormissibIo
imporfoclions in fIango-facing finisl. Tlo cloico of
fIango-facingfinisl slaII bo in accordanco vill llo appIi-
cabIo slandard and compalibIo vill llo roquiromonls
spocifiod by llo usor or rocommondod by llo gasIol
manufacluror. Ior oxampIo, unIoss ollorviso agrood lo
by llo purclasor or manufacluror, ASMI B16.5 spocifios
llo foIIoving fIango-facing finislos (as judgod by visuaI
comparison vill slandards por ASMI B46.1):
Tonguo and groovo and smaII maIo and fomaIo
fIangos: nol lo oxcood 3.2 m (125 in.) rouglnoss.
Ring joinl: nol lo oxcood 1.6 m (63 in.)
rouglnoss.
(08)
(08)

Ollor: Iillor a sorralod conconlric or sorralod spi-
raI finisl laving a rosuIling surfaco finisl from 3.2 m
lo 6.4 m (125 in. lo 250 in.) avorago rouglnoss slaII
bo furnislod. Tlo culling looI ompIoyod slouId lavo
an approximalo 1.5 mm (0.06 in.) or Iargor radius and
lloro slouId bo from 1.8 lo 2.2 groovos/mm (45 lo 55
groovos/in.).
4 FAkICA1I0h
4.1 kepair witheut weIding
If oillor llo fIango ring llicInoss or lub dimonsions,
or boll, aro sufficionl, llon llo onliro gasIol surfaco
may bo maclinod lo romovo llo aroa of dogradalion or
imporfoclion and aclioving llo dosirod finisl villoul
voId molaI buiIdup.
4.2 kepair by weIding
In ropairing a fIango faco, il may bo nocossary lo uso
voId molaI lo oillor fiII a IocaI aroa (for oxampIo, a
gougo or a scralcl) or lo voId buiIdup llo baso molaI
or oxisling voId ovorIay faco. Wloro llo fIango is lo bo
ropairod by voIding, llo aroa vloro llo buiIdup is lo
bo appIiod slaII bo froo of any rosiduo, corrosion dopos-
ils, olc., llal vouId unduIy affocl llo voId. CIoaning
may bo by moclanicaI or clomicaI procoduros. WoIding
procoduros and voIdor quaIificalions slaII compIy vill
llo roquiromonls of an appIicabIo nov conslruclion codo
(sucl as ASMI BIVC Soclion IX), or an appIicabIo
posl-conslruclion codo or slandard. Wloro voId molaI
buiIdup is nocossary, llo fiIIor molaI, voIding loclniquo,
voIdor quaIificalions, and loal lroalmonl (if any) slaII bo
soIoclod lo mool sorvico and molaIIurgicaI roquiromonls.
Surfaco conlaminanls romaining on llo fIango faco, sucl
as gasIol maloriaI rosiduo or corrosion doposils, can
rosuIl in voId dofocls sucl as porosily or incIusions and
slaII bo romovod prior lo porforming any voId molaI
buiIdup oporalion.
4.3 PestweId heat 1reatment
Wlon voId molaI buiIdup is roquirod, poslvoId loal
lroalmonl slaII bo porformod prior lo fIango faco
maclining if roquirod by an appIicabIo nov conslruclion
or posl-conslruclion codo. IoslvoId loal lroalmonl is
nol roquirod if llo llicInoss of llo voId molaI buiIdup
is Ioss llan llo maximum aIIovabIo fiIIol voId llroal
llicInoss unIoss dimonsionaI slabiIily is an issuo, or
poslvoId loal lroalmonl is roquirod for procoss roasons.
4.4 Machining
Tlo culling looI radius and food ralo slouId bo sol lo
proquaIifiod vaIuos in ordor lo consislonlIy acliovo llo
dosirod surfaco finisl. Ior minor imporfoclions, carofuI
fiIing may bo adoqualo for llo romovaI and drossing of
llo fIango facos.
95
4.5 Cenversien
In proparalion.
5 XAMIhA1I0h
5.1 Casket 5urIace
Tlo finislod surfaco slaII bo oxaminod lo compIy vill
llo roquiromonls of llo slandard appIicabIo lo nov
fIangos or as spocifiod by llo usor. Ior oxampIo,
ASMI B16.5 roquiros llal llo surfaco finisl bo judgod by
visuaI comparison vill llo slandards of ASMI B46.1.
5.2 hendestructive xaminatien
In casos vloro voId molaI buiIdup is usod in llo
ropair, llo aroa lo bo ropairod slaII bo oxaminod prior
lo porforming llo voId buiIdup using an approprialo
NDI mollod lo dolormino llo inlogrily of llo baso
molaI. Considoralion slaII bo givon lo oxamining oacl
voId pass for surfaco dofocls by oillor magnolic parlicIo
oxaminalion (MT) or Iiquid ponolranl oxaminalion (IT),
as approprialo. Ior oxampIo, sucl oxaminalion slouId
bo porformod for voIds suscoplibIo lo cracIing. Tlo
finislod maclinod surfaco slaII aIso bo oxaminod by
MT or IT, and imporfoclions in oxcoss of llo slandard
appIicabIo lo nov fIangos, or as spocifiod by llo usor,
slaII bo ropairod and rooxaminod by llo mollod llal
discovorod llo imporfoclion. GuidoIinos for nondoslruc-
livo oxaminalion can bo found in ASMI BIVCSoclion V.
Tlo MT or IT oxaminalion slaII bo conduclod in accor-
danco vill Appondix 6 or Appondix 8, rospoclivoIy, in
ASMI BIVC Soclion VIII, Division 1, or ollor appIicabIo
conslruclion codo, o.g., ASMI BIVC Soclion VIII,
Division 2.
5.3 imensiens
Aflor ropair, llo fIango llicInoss and ollor dimon-
sions slaII bo vorifiod for conformanco lo llo roquirod
llicInoss of llo appIicabIo slandard or as oslabIislod
by dosign caIcuIalion.
6 151IhC
Aflor llo fIango joinl is roassombIod in llo fioId, il
slouId bo subjoclod lo a IoaI losl prior lo boing pIacod
in sorvico, or an iniliaI sorvico IoaI losl. An iniliaI sorvico
IoaI losl is ono in vlicl llo joinl is monilorod for IoaIago
as prossuro is incroasod in llo syslom. Tlo soIoclion of
llo mosl approprialo losling mollod slaII considor llo
lazard of llo sorvico and any jurisdiclionaI roquiro-
monls. Ior gonoraI guidanco on fIangod joinl IoaI ligll-
noss losling, rofor lo Soclion 13 of ASMI ICC-1.
7 kFkhC5
7.1 FIange 5tandards
AII 660, SloII and Tubo Ixclangors for GonoraI Rofinory
Sorvico
(08)

ASMIB16.1, Casl IronIipo IIangos and IIangod Iillings
ASMI B16.5, Iipo IIangos and IIangod Iillings
ASMI B16.24, Bronzo Iipo IIangos and IIangod Iillings:
CIass 150, 300, 400, 600, 900 and 1500
ASMI B16.36, Orifico IIangos
ASMI B16.47, Iargo Diamolor SlooI IIangos NIS 26
Tlrougl NIS 60
96
Slandards of TubuIar Ixclangor Manufaclurors
Associalion
IubIislor: TubuIar Ixclangor Manufaclurors
Associalion, Inc. (TIMA), 25 Norll Broadvay, Tar-
rylovn, NY 10591

ArticIe 3.6
MechanicaI CIamp kepair
1 5CkIP1I0h
A moclanicaI cIamp consisls of spIil fillings moclani-
caIIy joinod logollor lo soaI off or roinforco a compononl.
IxampIos of moclanicaI cIamps aro iIIuslralod in
Iigs. 1 and 2.
MoclanicaI cIamps aro commonIy usod lo soaI ropair-
IoaIing compononls or roinforco damagod compononls.
MoclanicaI cIamps can lavo a varioly of slapos (o.g.,
cyIindricaI, roclanguIar, vill oillor fIal or formod
loads), oflon foIIoving llo conlour of llo pipo or compo-
nonl boing ropairod. MoclanicaI cIamps can aIso bo usod
lo oncIoso compononls sucl as fIangos and vaIvos or
fillings, branclos, nozzIos, or vonls and drains.
MoclanicaI cIamps aro oflon avaiIabIo as calaIog iloms
or lloy can bo cuslom-mado of lvo laIf sloIIs, a soaIing
gasIol and boIls, or sluds and nuls.
Tlo annuIar spaco bolvoon llo moclanicaI cIamp and
llo ropairod compononl can bo Iofl oillor omply or fiIIod,
or Iinod vill opoxy, soaIanl, fibor, rofraclory maloriaIs,
or ollor compounds.
A cIamp can bo nonslrucluraI (dosignod lo conlain
IoaIs) or slrucluraI (dosignod lo roinforco and loId
logollor a damagod compononl).
Fig. 1 xampIe eI a MechanicaI CIamp
97
2 LIMI1A1I0h5
2.1 CeneraI
2.2 AppIicabiIity
NormaIIy, moclanicaI cIamps aro usodlo conlain IoaIs
al pacIings, and al fIangod and gasIolod joinls, or lo
conlain IoaIs (or polonliaI IoaIs) duo lo IocaI llinning.
Tlo cIamp is nol aIvays offoclivo in provonling llo prop-
agalion of a cracI in llo pipo or compononl. Tloroforo,
IoaI cIamps slaII nol bo usod vlon cracIs aro prosonl,
unIoss
llo condilions llal Ioad lo llo cracI formalion and
propagalion lavo boon oIiminalod so llal llo cracI viII
nol grov during llo pIannod Iifo of llo ropair,
a filnoss-for-sorvico assossmonl slovs llal llo
cracI grovll during llo pIannod Iifo is accoplabIo, and
llal llo cracI viII nol propagalo across llo cIamp, or
llo cracI is circumforonliaI and llo cIamp is a
slrucluraI cIamp, vloro llo cIamp is dosignod for llo
caso of fuII circumforonliaI soparalion of llo cracIod
compononl. A soparalo slrong-bacI assombIy may bo
usod lo provido slrucluraI inlogrily, vliIo llo cIamp
onIy providos IoaI soaI. Il is common for lloso lvo iloms
lo bo indopondonl, llougl usod in concorl.
2.3 uaIiIicatiens
InslaIIalion and soaIanl injoclion, vloro nocossary,
slaII bo porformod by porsonnoI quaIifiod undor condi-
lions roprosonlalivo of llo fioId appIicalion.
2.4 5aIety
IorsonnoI slaII bo avaro of lazards in inslaIIing
cIamps on dogradod compononls, and slaII laIo llo
nocossary procaulions lo avoid unaccoplabIo risIs. ArisI
roviov slaII bo conduclod boforo a cIamp is inslaIIod.
IorsonnoI slaII laIo any nocossary procaulions lo avoid
unaccoplabIo risIs.
2.5 Precautiens
If llo compononl is IoaIing or las llo polonliaI lo IoaI
during inslaIIalion, and if llo conlonls aro lazardous,
addilionaI procaulions slouId bo laIon and lloso pro-
caulions slouId bo addrossod during llo projob lazard
roviov mooling (o.g., nood for frosl air suil, olc.).

Fig. 2 5quare MechanicaI CIamp 0ver rain ranch, with 5eaIant Injectien hezzIe
3 5ICh
3.1 MateriaIs
CIamp maloriaIs slaII bo Iislod in llo conslruclion or
posl-conslruclion codo, Iigs. 1 and 2, and bo compalibIo
vill llo fIuid, prossuro, and lomporaluro, vill duo con-
sidoralion for llo slagnanl condilion croalod by a IoaI
of fIuid inlo llo cIamp. Tlo moclanicaI cIamp soaIing
oIomonl and ils Iubricanl may provonl ils uso in ligl-
lomporaluro sorvico. GonoraIIy, llo maloriaI of conslruc-
lion of llo cIamp slouId bo simiIar lo llo cIampod com-
pononl. CIamps mado of difforonl maloriaIs slaII bo
accoplabIo if lloy aro compalibIo vill llo procoss and
oxisling compononls. Tlo cIamp dosign and conslruc-
lion, incIuding maloriaI soIoclion, slaII bo dono consid-
oring llo dolorioralion modo llal Iod lo llo nood for
llo ropair. Tlo cIamp slaII bo suilabIo for rosisling llis
dolorioralion modo for llo Iifo of llo ropair.
3.2 esign LiIe
Tlo dosign Iifo of llo ropair slaII bo basod on llo
romaining slrongll of llo ropairod compononl, llo corro-
sion rosislanco and moclanicaI proporlios of llo cIamp,
ils soaIing oIomonls and, vloro usod, llo soaIanl. Somo
soaIanls Ioso lloir soaIing proporlios as a lol Iino is
cooIod dovn, or llo soaIanl can dolorioralo ovor limo.
Tlis slaII bo considorod if Ioaving llo cIamp in pIaco
for a nov loal-up cycIo or boyond llo manufaclurors
dosignalod limo al lomporaluro.
98
3.3 FaiIure Medes
Tlo cIamp dosign slaII considor llo polonliaI inlro-
duclionof novfaiIuro modos in llo cIampod compononl.
Ior oxampIo:
IxlornaI parls of llo ropairod compononl, nov
oncIosod by llo cIamp, sucl as fIango boIls, llal couId
significanlIy dogrado, cracI, or corrodo if in conlacl vill
llo IoaIing fIuid.
Bocauso llo cIamp can bo al a Iovor lomporaluro
llan llo compononl, condonsalo from IoaIago gasos
slouId bo considorod for ils corrosivo offocls.
Tlo cIamp can causo llo compononl lo run al a
difforonl lomporaluro, vlicl can incroaso llo corrosion
ralo or causo dov-poinl corrosion.
Irocoss fIuid conlacl or llo insuIaling offocl of llo
cIamp may incroaso llo lomporaluro of oncapsuIalod
boIling, causing il lo yioId.
Tlo dovoIopmonl of oporal ing and rosiduaI
slrossos duo lo conslrainod difforonliaI oxpansion can
causo llo cIamp lo IoaI.
3.4 1emperature and 1eughness
Tlo cIamp maloriaIs slaII salisfy llo minimum lom-
poraluro and, vloro appIicabIo, minimum louglnoss

3.5 esign Cenditiens
MoclanicaI cIamps, soaIing surfacos, and boIling slaII
bo dosignod for dosign condilions and anlicipalod lran-
sionl Ioads imposod on llo ropairod pipo or compononl,
foIIoving llo dosign roquiromonls of llo conslruclion
3.6 uaIiIicatien
In casos vloro lloro aro no appIicabIo dosign roquiro-
monls, llo principIos of llo appIicabIo codo of conslruc-
lion or posl-conslruclion codo slaI I bo foI Iovod.
Compononls of llo moclanicaI cIamp llal aro fabricalod
by maclining slandard fillings (sucl as culling-oul an
oponing in slandard pipo caps lo maIo ond piocos) slaII
bo quaIifiod by anaIysis or losling, as providod in llo
codo, and bo roinforcod if nocossary.
3.7 Cerresien AIIewance
Tlo dosign of llo cIamp slaII incIudo llo appIicabIo
corrosion aIIovanco, consislonl vill llo sorvico and llo
dosign Iifo of llo ropair.
3.8 esign Leads
Tlo dosign of llo moclanicaI cIamp for normaI
oporaling condilions slaII considor llo foIIoving:
llo coincidonl maximum and minimum prossuros
and lomporaluros of llo syslom, unIoss moans aro pro-
vidod lo Iimil llo prossuro in llo moclanicaI cIamp.
Dosigning llo cIamp for a Iovor rango of dosign and
oporaling lomporaluros llan llo compononl is accopl-
abIo if juslifiod by loal lransfor anaIysis.
llo Ioad imposod by llo voigll of llo cIamp,
incIuding llo onlrappod IoaIing fIuid and annuIar spaco
maloriaI.
llo offocls of oxpansion, incIuding difforonliaI
oxpansion or conlraclion, and llo offocl on llo fIoxibiIily
of llo pipo or compononl. On insuIalod Iinos and compo-
nonls llo cIamp may aIso bo insuIalod lo minimizo dif-
foronliaI oxpansion.
3.9 1ransient Leads
Anlicipalod lransionl Ioads for uso in llo dosign of
slrucluraI cIamps slaII incIudo, bul aro nol Iimilod lo
llrusl Ioads, in caso of fuII circumforonliaI sopara-
lion of llo pipo or compononl. Dosign for llo axiaI llrusl
rosuIling from fuII circumforonliaI soparalion may bo
vaivod, providod llo caIcuIalod romaining slrongll of
llo dogradod compononl al llo ond of llo dosign Iifo
(incIuding oxpoclod conlinuing dogradalion in sorvico)
is dolorminod lo bo sufficionl. AddilionaI roslrainls may
bo addod lo llo pipo or compononl lo roduco llo Ioads
on llo cIamp.
Wloro a cIamp is inlondod lo roslrain IongiludinaI
forcos, a IocIing moclanism or slrong-bacI slaII bo pro-
vidod lo provonl soparalion. Iriclion slouIdnol bo roIiod
99
on lo loId logollor damagod or soparalod compononls
in a fIuid sorvico llal is fIammabIo, loxic, or damaging
lo luman lissuos, or if llo compononls oporalo in llo
croop rango, unIoss a risI anaIysis documonls llal llo
risI of faiIuro of llo cIampod joinl is accoplabIo.
vind, oarllquaIo, or fIuid lransionls (fIuid lam-
mor or Iiquid sIug), as appIicabIo.
3.10 vents and rains
Wlon ropairing a IoaIing compononl, llo moclanicaI
cIamp assombIy slouId bo dosignod vill vonls and
drains lo pormil vonling llo IoaI vliIo assombIing llo
cIamp, llon draining llo annuIus as nocossary.
Vonls slouId aIso bo providod for moclanicaI
cIamps inslaIIod undor valor lo avoid ovor-prossurizing
llo valor lrappod in llo annuIus as llo cIamp is
ligllonod.
Tlo vonl or drain slouId incIudo a llroadod cap,
a fIango, or a vaIvo llal viII bo oponod lo procIudo
inlornaI prossuro buiIdup during assombIy. Tlis samo
vonl or drain may bo usod lo vonl or drain llo cIamp
in llo fuluro. If IoaI soaIanl maloriaI is lo bo injoclod
inlo llo cIamp, lloso vonl and drain connoclions may
bo usod, or soparalo injoclions may bo providod.
3.11 5eund MetaI
Tlo cIamp slaII bo sufficionlIy Iong lo oxlond lo a
sound aroa of llo ropairod compononl. Tlo cIampod
compononl slaII bo oxaminod lo onsuro llal lloro is
sufficionl vaII llicInoss al llo cIamp conlacl poinls lo
carry llo prossuro and slrucluraI Ioads inllo compononl,
pIus llo addilionaI Ioads imposod by llo cIamp.
3.12 5eaIant Pressure
If using soaIanl injoclion, llo possibiIily of invard
coIIapso of llo cIampod compononl duo lo llo annuIus
prossuro of llo injoclod soaIanl slaII bo considorod.
Considoralion slouId bo givon lo off-gassing of soaI-
anl compounds as lloy curo.
3.13 5eaIant 5eepage
If using soaIanl injoclion, llo possibiIily and conso-
quonco of soaIanl sooping inlo llo damagod compononl
3.14 [eints
CIamps ovor oxpansion joinls, sIip joinls, baII joinls,
olc., aro spociaI casos llal slaII roquiro anaIysis of llo
Ioads in llo pipo syslom, anclors, and compononl noz-
zIos vill llo cIamp inslaIIod, vill duo considoralion
for llormaI-inducod movomonls in oporaling and slul-
dovn condilions.
4 FAkICA1I0h
4.1 Preparatien
Tlo compononl lo vlicl llo cIamp viII bo allaclod
slouId bo froo of Iooso corrosion doposils, dirl, painl,

insuIalion, maslics, and ollor coalings in llo vicinily of
llo moclanicaI cIamp inslaIIalion, in parlicuIar llo aroa
vloro llo soaIing surfacos viII conlacl llo prossuro com-
pononl. Tloso subslancos can provonl llo soaIing sur-
facos from soaling proporIy againsl llo prossuro
compononl or ollorviso gonoralo a IoaI pall undor llo
soaIing surfacos. CIamps using soaIanl injoclion viII gon-
oraIIy ovorcomo lloso concorns.
4.2 Leak ex InstaIIatien
Caro slaII bo laIon so as nol lo damago llo cIamp,
ospociaIIy llo soaIing surfacos. Ior smaII IoaIs, llo cIamp
can lypicaIIy bo pIacod diroclIy ovor llo IoaI. Iargor or
liglor prossuro inslaIIalions lypicaIIy roquiro llo
moclanicaI cIamp bo IoosoIy inslaIIod on llo compononl
lo llo sido of llo IoaI and llon sIid and ligllonod ovor
llo IoaI.
4.3 uaIiIicatien
IorsonnoI slaII bo quaIifiod for inslaIIing llo ropair
cIamp and soaIanl injoclion, vlon soaIanl is appIiod.
4.4 In-5ervice InstaIIatien
Tlo cIamp may bo inslaIIod vlon llo syslom is oul
of sorvico or, vill llo nocossary safoly procoduros, in
sorvico.
4.5 Leak 5teppage
If a moclanicaI cIamp is inslaIIod ovor a llinnod or
IoaIing compononl, considoralion slouId bo givon lo
vrapping llo compononl vill fiborgIass, composilo, or
molaIIic vraps sucl llal llo IoaI can bo sloppod prior lo
inslaIIing llo cIamp. Tlis viII aIso provonl inlroducing
soaIanl inlo llo procoss. Tlis may aIso aid in fuluro
soaIing, if llo porimolor slarls IoaIing.
4.6 weIding
Tlo moclanicaI cIamp may bo voIdod lo llo compo-
nonl. In llis caso, llo voIding, oxaminalion, and losling
provisions for IoaI ropair boxos slaII bo roviovod for
appIicabiIily lo llo ropair.
5 XAMIhA1I0h
5.1 AppIicabiIity
Tlo finaI boIling lorquo slaII bo clocIod vloro spoci-
fiod by dosign.
100
Tlo assombIy slaII bo visuaIIy oxaminod for confor-
manco vill llo dosign.
5.3 vaIuatien
RosuIls of oxaminalions slouId bo ovaIualod foIIov-
ing llo criloria of llo appIicabIo codo of conslruclion or
6 151IhC
6.1 AppIicabiIity
Tlo dosignor slaII dolormino llo lypo of prossuro or
IoaI losl lo bo conduclod aflor inslaIIalion, on llo basis
of risI IiIoIilood and consoquonco of faiIuro of llo
ropairod compononl vlon prossurizing llo annuIus
bolvoon llo cIamp and llo compononl.
6.2 1est Methed
Tlo losl may consisl of ono of llo foIIoving:
an in-sorvico IoaI losl if llo consoquonco of an in-
sorvico IoaI oul of llo cIamp is accoplabIo
a lydroslalic losl (vlon lydroslalicaIIy losling a
ropair on a lol oporaling syslom, caulion is roquirod lo
avoid llo disclargo of fIasling losl valor)
a pnoumalic prossuro losl
a sonsilivo IoaI losl (sucl as air vill bubbIo soIu-
lion, or loIium IoaI losl)
7 kFkhC5
AII 510, Irossuro VossoI Inspoclion Codo: Mainlonanco,
Inspoclion, Raling, Ropair and AIloralion
AII 570, Iiping Inspoclion Codo: Inspoclion, Ropair,
AIloralion, and Roraling of In-Sorvico Iiping Sysloms
Slrool, NW, Waslinglon, DC 20005-4070.
ASMI BoiIor and Irossuro VossoI Codo, Soclion VIII
RuIos for Conslruclion of Irossuro VossoIs

ArticIe 3.7
Pipe 5traightening er AIignment ending
1 5CkIP1I0h
Tlis ArlicIo addrossos llo roquiromonls and caulions
for llo slraiglloning of bonl molaIIic pipo and inlon-
lionaI bonding of molaIIic pipo lo accommodalo aIign-
monl, fil-up, or ropair. Slraiglloning and aIignmonl
bonding can bo acliovod by lol bonding, coId bonding,
or by loaling and cooIing.
2 LIMI1A1I0h5
2.1 CeneraI
2.2 uckIing Preventien
If llo pipo is Iinod, or is prono lo bucIIing (o.g., if ils
oulor diamolor dividod by ils vaII llicInoss / is Iargor
llan 100), an onginooring ovaIualion slaII bo porformod
prior lo allompling llo slraiglloning oporalion.
2.3 MateriaIs
An onginooring ovaIualion slouId bo conduclod lo
vaIidalo llal llo pipo and voId maloriaI proporlios aro
nol advorsoIy affoclod by loaling or bonding. Soo paras.
2.3.1 and 2.3.2.
2.3.1 Hoaling or doformalion of llo pipo may
causo llo Ioss of corrosion or cracIing rosislanco, sucl
as llo sonsilizalion of soIulion-annoaIod auslonilic slain-
Ioss slooIs, or llo accumuIalion of rosiduaI slrossos llal
can Ioad lo slross corrosion cracIing in causlic sorvico.
2.3.2 Hoaling onlancod slrongll and louglnoss
Iov aIIoy slooIs and lardonabIo ligl aIIoy slooIs abovo
lloir finaI loal lroalmonl lomporaluro may dogrado
moclanicaI proporlios.
2.4 Linings and Ceatings
Tlo bonding oporalion may damago inlornaI Iinings
or oxlornaI coalings.
2.5 hazards keview
Tlo nood for a lazards roviov slouId bo considorod
prior lo lol or coId bonding, lo addross llo Iimilalions
in llis ArlicIo, and ollor faciIily and syslom-spocific
considoralions.
101
3 5ICh
3.1 Preventing kecurrence
An invosligalion inlo llo causo of damago slouId bo
compIolod and approprialo corroclivo aclion slouId bo
impIomonlod lo provonl fuluro damago.
3.2 AnaIysis
Tlo slraiglloning oporalion slouId bo dosignod by
an oxporioncod piping dosign onginoor. Tlo oporalion
slaII avoid pIacing significanl Ioads on nozzIos, oquip-
monl, compononls, or supporls in oxcoss of lloir dosign
capacily.Tlis may bo acliovod by appIying llo pIannod
movomonl lo a slross anaIysis modoI of llo piping,
oblaining roaclion forcos al nozzIos, oquipmonl, compo-
nonls, and supporls and vorifying llal lloso romain
villin accoplabIo Iimils, as spocifiod by oquipmonl,
compononl, and supporl manufacluror or by llo dosign
ruIos of llo appIicabIo codo of conslruclion or
posl-conslruclion codo. CaIcuIalod slrossos in llo pipo
ilsoIf and al pipo voIds may bo Iargo, bocauso llo bond-
ing procoss viII pIaslicaIIy doform llo pipo. Iargo
slrossos in llo pipo ilsoIf or in llo pipo voId, avay from
nozzIos, oquipmonl, compononls, or supporls may bo
accoplabIo, providod ollor condilions spocifiod in llis
ArlicIo aro mol.
3.3 Lead and eIermatien Limits
AppIiod Ioads and doformalions al moclanicaI joinls
sucl as fIangod joinls, llroadod joinls, svago fillings,
oxpansion joinls, or comprossion fillings slaII bo villin
llo joinl dosign and manufacluror Iimils.
3.4 kesiduaI ChemicaIs
If rosiduaI procoss clomicaIs couId prosonl a safoly
lazard al llo bonding lomporaluro, oillor diroclIy or by
dograding llo piping maloriaI, llo bonding procoduro
slaII bo roviovod for polonliaI lazards, prior lo slarling
llo vorI. Tlo roviov slaII vaIidalo llal llo rosiduaI
clomicaIs, vlon loalod, viII noillor dogrado llo pipo
nor causo a lazardous condilion. Ollorviso, llo pipo
slaII bo llorouglIy cIoanod prior lo lol bonding.
4 FAkICA1I0h
4.1 Metheds
Slraiglloning a pipo may bo porformod by pusling
or puIIing llo pipo bacI inlo llo dosirod posilion, oillor

using a pipo-bonding maclino or jacIs and puIIing
dovicos, or by IocaIIy loaling llo pipo and llon cooIing
il lo acliovo llo dosirod slapo, appIying llo procaulions
spocifiod in llis ArlicIo.
4.2 5urIace Pretectien
Wlon using jacIs or puIIing dovicos, a pad slouId bo
usod bolvoon llo clain or ropo and llo pipo lo avoid
oxcossivo friclion, voar, IocaI slrossos, or donls and
gougos on llo pipo surfaco. Wloro possibIo, IocaI slrain-
ing of llo pipo slouId bo avoidod by dislribuling llo
slraiglloning or aIignmonl forco ovor a vido aroa.
4.3 het er CeId ending
Iipo may bo slraigllonod by lol or coId bonding,
providod aII llo caulions and condilions of llis ArlicIo
aro mol.
4.3.1 Tlo lol bonding rofors lo bonding of forrilic
slooIs al a lomporaluro abovo llo Iovor crilicaI lompora-
luro of llo maloriaI
cril
. Tlo Iovor crilicaI lomporaluro
is llo Iovosl lomporaluro al vlicl llo cryslaI slrucluro
firsl bogins lo undorgo an aIIolropic lransformalion from
a body-conlorod cubic (BCC) alomic slrucluro lo a faco-
conlorod cubic (ICC) alomic slrucluro. Tlo approximalo
Iovor crilicaI lomporaluro for carbon slooI pipo is 705C
(1,300I).
Croop-onlancod Iov aIIoy forrilic slooIs sucl as lloso
incIudod in I-No. 5B, Group 2 of ASMI BIVCSoclionIX,
slouId nol bo lol bonl. Tloso maloriaIs aro sonsilivo lo
loaling abovo lloir Iovor lransformalion lomporaluro,
vlicl is a funclion of lloir clomicaI composilion. Hoal-
ing lloso maloriaIs abovo lloir Iovor lransformalion
lomporaluro couId rosuIl in llo Ioss of lloir ligl-
lomporaluro proporlios.
Wlon using loal on piping llal las boon in sorvico,
oillor for lol bonding or for IocaI loaling during coId
bonding, llo loaling procoss slaII bo soIoclod (o.g., using
loaling pads rallor llan a culling lorcl) and conlroIIod
(o.g., using lomporaluro-indicaling marIors or llormo-
coupIos) lo provonl uninlondod molaIIurgicaI lransfor-
malion or slross damago. A documonlod loaling and
lomporaluro conlroI procoduro slaII bo foIIovod.
4.3.2 CoId bonding rofors lo bonding boIov
cril
.
Tlo pipo may bo bonl coId if pormillod by llo appIicabIo
codo of conslruclion or posl-conslruclion codo. CoId
bonding may roquiro loaling boIovllo crilicaI lompora-
luro, loaling is usuaIIy on llo sido llal noods lo bo
slorlonod and is appIiod in a diamond pallorn.
4.4 heat 1reatment
Ioslslraiglloning loal lroalmonl of coId-bonl or lol-
bonl pipo slaII bo porformod vloro roquirod by llo
codo or maloriaI spocificalion for llo bonding of nov
pipo, or vlon roquirod for corrosion rosislanco.
102
5 XAMIhA1I0h
5.1 AppIicabiIity
Aflor slraiglloning or bonding llo pipo, llo oxamina-
lions spocifiod in paras. 5.1.1 llrougl 5.1.4 slaII bo con-
sidorod.
5.1.1 UIlrasonic llicInoss oxaminalion lo vorify
llal llo vaII llicInoss is al or abovo llo minimum
roquirod by llo appIicabIo codo of conslruclion or posl-
conslruclion codo pIus corrosion aIIovanco. Tlis oxami-
nalion slouId bo porformod al llo oulsido radius (poinls
pIacod in lonsion by bonding) al poinls of maximum
bonding.
5.1.2 VisuaI oxaminalion lo vorify llal llo slraigll-
onod pipo is froo of vrinIIos, croasos, donls, gougos,
poaIs, and ollor signs of damago. If damago is nolod,
llo damago may bo assossod using llo criloria of llo
Iipo Iabricalion Inslilulos Inginooring Slandard IS-24,

, and llo appIicabIo codo of conslruclion or
Wloro surfaco finisl is spocifiod in llo dosign, il slaII
bo vorifiod aflor llo slraiglloning or bonding oporalion.
Tlo visuaI oxaminalion slaII aIso addross llo inlogrily
of Iining and coaling.
5.1.3 DimonsionaI oxaminalion for ovaIily (Iargosl
roIalivo difforonco of diamolors al a cross soclion of llo
pipo) lo vorify llal il is nol moro llan llal pormillod
by llo appIicabIo codo of conslruclion or posl-
conslruclion codo.
5.1.4 Hardnoss losling aflor lol bonding (or IocaI
loaling) of loal-lroalabIo pipo, lo vaIidalo llal loaling
las nol unduIy aIlorod llo maloriaI proporlios, is in
ordor. Tlo lardnoss slaII bo Iimilod lo vaIuos spocifiod in
codo, or as spocifiod by llo dosign or by llo maloriaIs
and corrosion onginoor.
5.2 weId xaminatien
If llo slraigllonod pipo conlains voIds (IongiludinaI
or girll voIds) lloso voIds slaII bo oxaminod for codo
rojoclabIo indicalions by oillor magnolic parlicIo or Iiq-
uid ponolranl mollod, as approprialo, and ovaIualod in
6 151IhC
6.1 AppIicabiIity
Tlo slraigllonod pipo slaII bo prossuro loslod, if
roquirod by llo appIicabIo posl-conslruclion codo.

6.2 5peciaI Censideratien
Considoralion slouId aIso bo givon lo vlollor llo
risI of a IoaI or rupluro on slarlup juslifios prossuro or
IoaI losling in llo absonco of codo roquiromonls.
6.3 AIternative
In llo absonco of prossuro losling, an iniliaI sorvico
IoaI losl slouId bo considorod, consisling of visuaI
103
oxaminalion for IoaIs in Iiquid or sloam sorvico, or bub-
bIo losling for gas sorvico.
7 kFkhC
Slandard IS-24, Iipo Bonding Mollods, ToIorancos,
Irocoss and MaloriaI Roquiromonls
IubIislor: Iipo Iabricalion Inslilulo (III), 666 Iifll
Avonuo, Nov YorI, NY 10103

ArticIe 3.8
amaged Anchers in Cencrete
(PestinstaIIed MechanicaI Anchers)
1 5CkIP1I0h
1.1 Ancher bses
Anclors aro noodod for mosl baso pIalos. Tloy aro
usod lo safoIy anclor baso pIalos lo provonl coIumn
ovorlurning and lloy aro aIso nocossary vlon llo baso
pIalo is subjocl lo Iargo dosign momonls or upIifl.
Anclors aro primariIy lonsion dovicos. To provonl llo
anclor from puIIing oul of llo concrolo, slouId llo bond
slrossos bo oxcoodod, looIs, pIalos, or ollor slapos aro
addod lo llo omboddod porlion of llo anclor.
1.2 Intent
Tlis ArlicIo is gonoraIIy vrillon vill rogards lo
ropairing coIumn baso moclanicaI anclors. Tloroforo,
llo omplasis of llis ArlicIo is on poslinslaIIod moclani-
caI anclors as doscribod in para. 1.6. Hovovor, il is
inlondod lo appIy lo ropairing prossuro vossoI supporl
anclors, sucl as, supporl sIirls and saddIo supporls.
1.3 1ypes eI MechanicaI Anchers
Tloro aro lvo gonoraI lypos of moclanicaI anclors:
casl-in-pIaco and driIIod-in. Tlroo difforonl lypos of casl-
in-pIaco anclors aro slovn in Iig. 1. Tloso aro gonoraIIy
mado from oillor boIls or bar slocI, roforrod lo as a rod.
Tlo commonIy usod looIod rod is mado from a round
slapo and slovn in Iig. 1, iIIuslralion (a). Tlo lonsiIo
Ioad is rosislod llrougl a bond dovoIopod aIong llo
Iongll and by llo looI. Smooll rods do nol aIvays
Fig. 1 Anchers

104
form roIiabIo bonds duo lo oiI or ollor conlaminanls
llal may oxisl on llo rod. Tloso vill looIs may faiI
by slraiglloning and puIIing oul of llo concrolo. A moro
posilivo anclorago is oflon proforrod.
1.4 IIIustratiens
A moro posilivo anclorago is formod vlon boIls or
rods vill llroads and a nul aro usod, as slovn in Iig. 1,
iIIuslralions (b) and (c). Boaring on llo load or nul llon
dovoIops llo anclorago. Il is onIy nocossary lo provido
for adoqualo ombodmonl dopll and odgo dislanco. Sinco
loadod boIls aro nol oflon avaiIabIo in Ionglls and diam-
olors roquirod for baso pIalos, llo dosignor slouId gonor-
aIIy spocify llo rod vill llroadod onds and provision
of a nul for anclorago, as slovn in Iig. 1, iIIuslralion
(c). Tlo Iovor nul slouId bo fixod lo llo rod (o.g., lacI-
voIdod, loo mucl loal during llo voIding procoss may
advorsoIy affocl llo slrongll of llo rod) so llal llo rod
doos nol lurn oul vlon llo lop nul is ligllonod. Tlo
lacI voIds slaII bo pIacod al llo rod ovorlang faco of
llo nul, llis praclico is accoplod by llo ASMI Irossuro
VossoI Codo for nonslrucluraI lacI voIds usod as a IocI-
ing dovico ovon llougl voIding is nol ollorviso pormil-
lod for rod maloriaIs, sucl as A-193-B7.
1.5 Ancher FaiIure
Tlo lvo mosl common causos of anclor faiIuro aro
corrosion and IacI of propor proIoad. Anclor faiIuros
|soo Iig. 2, iIIuslralion (a)] occur vlon oillor llo boIl
faiIs moclanicaIIy (i.o., slooI faiIuro, puII-llrougl, or
puIIoul) or vlon concrolo surrounding llo anclor faiIs
(i.o., concrolo broaIoul or concrolo spIils) duo lo llo
lonsiIo and/or sloar Ioading of llo anclor |soo Iig. 2,
iIIuslralions (b) and (c)].
1.6 PestinstaIIed MechanicaI Ancher
Tlis ArlicIos omplasis is on poslinslaIIod moclanicaI
anclors of M6 (0.25 in.) diamolor or Iargor, pIacod inlo
prodriIIod loIos and anclorod villin llo concrolo by
moclanicaI moans. WliIo dala conlainod in llo various
labIos is Iimilod lo a maximum diamolor of M24 (1 in.),
llo mollodoIogy conlainod in llis documonl appIios lo
Iargor diamolor anclors found in procoss oquipmonl
supporls. Hovovor, many difforonl poslinslaIIod adlo-
sivo anclors llal aro anclorod by clomicaI moans (o.g.,
opoxy) aro avaiIabIo for uso in concrolo. Tloso anclors

Fig. 2 Ancher and Cencrete FaiIure
105
Fig. 3 CeIumn ase Anchers in Cencrete
oxlibil a rango of vorIing principIos, propriolary

dosigns, and porformanco claraclorislics and llus aro
nol llo primary omplasis of llis documonl. Tloso adlo-
sivo anclorod boIls aro accoplabIo for uso as Iong as lloy
aro inslaIIod por llo manufaclurors rocommondalions.
Bocauso of llo incroasing popuIarily of llis lypo of
anclor, Mandalory Appondix I conlains somo inslaIIa-
lion dala for adlosivo anclors.
1.7 CeIumn ase MechanicaI Ancher
An oxampIo of a coIumn baso moclanicaI anclor in
concrolo is slovn in Iig. 3. Nolo, llis is nol a poslin-
slaIIod anclor bul an originaI-inslaIIod anclor. Hov-
ovor, ovon llougl Iig. 3 doos nol slov ollor lypos, llis
ArlicIo is aIso appIicabIo lo ollor procoss oquipmonl
supporls, sucl as vossoI sIirls, lubuIar coIumns, and
saddIo supporls.
2 LIMI1A1I0h5
2.2 Censideratiens
In appIying llis ropair mollod, considoralion slaII bo
givon lo compalibiIily of maloriaIs, oporaling condi-
lions, inlondod Iifo of llo compononl, and any Iimila-
lions on oxaminalion and losling.

3 5ICh
3.1 0riginaI Ancher AssembIy
Tlo dosign of llo originaI anclor assombIy slouId bo
in accordanco vill llo originaI conslruclion codo, sucl
as llo Amorican Inslilulo of SlooI Conslruclion (AISC),

(nov obsoIolo) or llo
Amorican Concrolo Inslilulo (ACI) 318-02,
.
3.2 esign Censideratiens
Tlo dosign iloms spocifiod in paras. 3.2.1 llrougl 3.2.3
aro providod for considoralion vlon maIing ropairs lo
llo originaI anclor assombIy.
3.2.1 mbedment. Anclors of any lypo slaII lavo
an ombodmonl Iongll sufficionl lo dovoIop llo fuII
slrongll of llo anclor. DriIIing is oflon compIicalod by
llo prosonco of roinforcing rods. SlouId ono or moro bo
oncounlorod, an anaIysis slaII bo porformod lo dolor-
mino if il is pormissibIo lo llo roinforcing rods,
(i.o., by culling llo roinforcing rods as lloy aro oncoun-
lorod, a roduclion in llo slooI roinforcing aroa viII occur
sucl llal llo concrolo dosign may bo compromisod).
Anclors, vlon usod vill llo IovoIing nul mollod of
solling coIumn basos, slaII lavo a nul and loavyoroclion
vaslor boll abovo and boIov llo baso pIalo. Tlo vasl-
ors aro usod lo provonl llo nuls from allompling lo pusl
llrougl llo ovorsizod loIos. Ixlra llroad slouId bo
suppIiod for Iovor nul adjuslmonl.
3.2.2 Leading. Any anclor llal las boon sizod by
caIcuIalions basod on dosign Ioadings slaII bo proIoadod
sufficionlIy lo provonl oillor baso-pIalo soparalion from
foundalion or movomonl on llo foundalion vlon Ioads
aro appIiod. If proIoad is Ioss llan maximum Ioad in
sorvico, anclor boIl faliguo may occur. Ioriodic ligll-
oning is roquirod lo componsalo for llo proIoad Ioss duo
lo llo roIaxalion of llo concrolo. Anclors aro llo IinI
bolvoon foundalion and coIumn. Wlon a coIumn baso
is subjocl lo upIifl, llo upIifl forco musl bo rosislod by
a voigll groalor llan llo upIifl forco, or llo coIumn
baso musl bo anclorod. Anclors lransmil llis lonsion
forco. SovoraI claraclorislics in anclor dosign can bo
variod lo suil llo Ioad roquiromonls: llo quanlily of
boIls, llo diamolor, llo Iongll, and lypo of maloriaI.
3.2.3 5hear Ferces. Anclors lypicaIIy aro nol usod
lo rosisl sloar forcos in a coIumn baso. WliIo baso pIalo
friclion rosisls sloar, sloar forcos can bo furllor rosislod
by somo dovico allaclod lo llo undorsido of llo baso
pIalo and insorlod inlo a groovo or Ioyvay in llo con-
crolo foundalion. Tlo main roason anclors aro nol bo
usod lo rosisl sloar forcos is llal lloy lavo a roIalivoIy
Iov-bonding rosislanco. If a baso pIalo voro lo oaso sido-
vays inlo boaring againsl an anclor, llo Ioad (dis-
counling llo groul) vouId bo doIivorod approximaloIy
106
Fig. 4 weId kepair eI xisting ked
25 mm (1 in.) abovo llo concrolo lop. Tlo anclor vouId

acl IiIo a vorlicaI canliIovorod mombor. AIso, llo random
Iocalion of anclors as lloy aro Iocalod in llo ovorsizod
baso pIalo loIos rosuIls in a silualion vloro soIdom doos
moro llan ono anclor of a muIlianclor group go inlo
sloar al any ono limo. ACI 318 maIos aIIovanco for
sloar capacily on concrolo anclor boIls. Tlo capacily is
roducod in prosonco of groul lo accounl for bonding.
4 FAkICA1I0h
4.1 weId kepair eI xisting keds
Anclors, fabricalod from A36 or A307 llal broaI off
al llo surfaco bul do nol dislurb llo surrounding con-
crolo may lavo a llroadod rod oxlonsion voIdod lo llo
lop of llo boIl (soo Iig. 4). Tlo voId ropair slaII incIudo
moans lo avoid damago lo llo concrolo. Tlo maloriaI of
conslruclion of llo rod slaII bo Inovn. Anclors mado
of maloriaIs vill proporlios acliovod by loal lroalmonl
(o.g., quoncl and lomporod) slaII nol bo voId ropairod.
AWS D1.4 is a roforonco for guidanco on voIding con-
crolo omboddod slooI.
4.2 kepair eI xisting keds with xtensiens
Ior anclors fabricalod from A36, A307, and A-193-B7,
a sIoovo coupIing may bo usod vill a slorl llroadod
rod oxlonsion, providod llo loIo in llo baso pIalo is
Iargo onougl lo onsuro llal il cIoars llo coupIing (soo
Iig. 4).
4.3 kepIacement
Aflor romoving llo nul and vaslor, a carbido bil cul-
ling looI may bo pIacod ovor llo prolruding boIl and a
circuIar oponing driIIod in llo slooI baso pIalo, sIigllIy
Iargor llan llo boIl diamolor, oxposing llo concrolo
around llo damagod boIl. A diamond bil driII may llon
bo usod lo cul llrougl llo concrolo al sufficionl dopll

1abIe 1 Minimum dge istance Ier Punched,
keamed, er riIIed heIes

M6 (
1
/
) 13 (
1
2
) 10 (
3
8
)
M10 (
7
16
) 19 (
3
/
) 19 (
3
/
)
M12 (
1
2
) 22 (
7
8
) 19 (
3
/
)
M16 (
5
8
) 29 (1
1
8
) 22 (
7
8
)
M20 (
3
/
) 32 (1
1
/
) 25 (1)
M2/ (1) // (1
3
/
) 31 (1
1
/
)
6FhFkAL hUTF: Thls data ls prcvlded as an lllustratlve example cf
typlcal llmlts and shculd nct be used as reference data wlthcut
flrst valldatlng ln acccrdance wlth the appllcable deslgn ccde cr
manufacturers speclflcatlcn.
1abIe 2 xpansien Ancher IIIustrative xampIe eI 1ypicaI Minimum Limits Ier keIerence

M6 (
1
/
) 29 (1
1
8
) . . . 6/ (2
1
2
) . . . 31 (1
1
/
) . . .
M10 (
7
16
) /1 (1
5
8
) 75 (3) 9/ (3
3
/
) 113 (/
1
2
) /7 (1
7
8
) 125 (5)
M12 (
1
2
) 56 (2
1
/
) 100 (/) 125 (5) 152./ (6) 6/ (2
1
2
) 175 (7)
M16 (
5
8
) 69 (2
3
/
) 125 (5) 156 (6
1
/
) 188 (7
1
2
) 78 (3
1
8
) 213 (8
1
2
)
M20 (
3
/
) 81 (3
1
/
) 150 (6) 188 (7
1
2
) 225 (9) 9/ (3
3
/
) 250 (10)
M2/ (1) 113 (/
1
2
) 200 (8) 250 (10) 300 (12) 125 (5) 325 (13)
6FhFkAL hUTF: Thls data ls prcvlded as an lllustratlve example cf typlcal llmlts and shculd nct be used as reference data wlthcut flrst
valldatlng ln acccrdance wlth the appllcable deslgn ccde cr manufacturers speclflcatlcn. lt ls up tc the deslgner tc determlne values fcr
dlameters greater than M2/ (1 ln.). Thls data table shculd nct be extrapclated.
hUTF:
(1) ls the center-tc-center dlstance between twc ad|acent expanslcn anchcrs. The twc expanslcn anchcrs may be cn the same cr cn twc
dlfferent plate assemblles. Mlnlmum spaclng between anchcrs cf dlfferent dlameters shall be the average cf the mlnlmum spaclng fcr
lndlvldual dlameters.
lo oxlracl llo damagod or corrodod boIl. Tlo carbido
bil driII may aIso bo usod lo cul llrougl llo bonl Iogs
of I or } boIls. Caro slouId bo laIon lo avoid culling
robar, unIoss approvod by a slrucluraI onginooring
ovaIualion.
Anclors oxorl roIalivoIy smaII IaloraI Ioad on baso
pIalos, lloroforo loar-oul is lypicaIIy nol a probIom.
TabIo 1 conlains dimonsions basod on anclor sizo.
NOTI: TabIos 1 and 2 aro providod as iIIuslralivo oxampIos.
WliIo driIIing of baso pIalo loIos is llo proforrod
mollod for loIos of 38 mm (1.5 in.) in diamolor or
smaIIor, burning of baso pIalo loIos is an accoplabIo
procoduro for Iargor loIos, ospociaIIy vlon appIiod lo
fioId ropair silualions. Tlo sIigll lardoning oxlibilod
al llo burnod odgo is nol imporlanl sinco llo boaring
of llo anclor againsl llo sido of llo loIo is nol a faclor,
il maIos IillIo difforonco lov llo loIo is mado. Wlon
107
sizing llo aroa of a baso pIalo, llo Ioss of aroa al llo
anclor loIos (and groul loIos) is gonoraIIy ignorod.
Tvo of llo mosl commonIy usodposlinslaIIod anclors
aro llo and llo anclors. Iaragrapls 4.3.1
and 4.3.2 Iisl inslaIIalion inslruclions for oacl.
4.3.1 wedge Ancher InstaIIatien Instructiens.
MoclanicaI vodgo anclors roquiro groalor concrolo
slrongllduo lo llo conconlralion of slrossos al llo oxpan-
sion cIip. Tlo anclor vorIs by oxpansion in llo lip, and
llus IocaIizos aII of llo prossuro in a smaII aroa. Tlis
can causo llo concrolo lo cracI or, if llo concrolo is voaI,
llo anclor may nol ligllon. Tlis anclor can onIy bo
usod in concrolo, nol in masonry. Tlo foIIoving aro
vodgo anclor inslaIIalion inslruclions (soo Iig. 5):
DriII llo loIo porpondicuIar lo llo vorI surfaco.
Do nol roam loIo or aIIov llo driII lo vobbIo.

Fig. 5 wedge Ancher
Fig. 6 5Ieeve Ancher
DriII llo loIo doopor llan llo inlondod
ombodmonl dopll of llo anclor, bul nol cIosor llan lvo
anclor diamolors lo llo bollom surfaco of llo concrolo.
CIoan llo loIo using comprossod air as llis is
nocossary for propor anclor porformanco.
IIaco anclor in loIo. May roquiro slriIing vill a
lammor, duo lo friclion fil anclor dosign, lo oblain
propor anclor dopll.
IIaco vaslor and nul on anclor and ligllon lo
lorquo vaIuos Iislod in manufaclurors spocificalion.
4.3.2 5Ieeve Ancher InstaIIatien Instructiens
NOTI: A sIoovo anclor vill a vrappod slool molaI sIoovo, as
slovn in Iig. 6, is a Iigll-duly anclor and slouId nol bo usod for
baso pIalo appIicalions. Tloro aro loavy-duly sIoovo anclors llal
vorI as oxpansion anclors bul lloy aro nol slovn loro. Tlo
iIIuslralion is for inslaIIalion informalion onIy.
Tlo foIIoving aro sIoovo anclor inslaIIalion
inslruclions:
108
DriII llo loIo porpondicuIar lo llo vorI surfaco.
Do nol roam loIo or aIIov llo driII lo vobbIo.
DriII llo loIo doopor llan llo inlondod
ombodmonl dopll of llo anclor, bul nol cIosor llan lvo
anclor diamolors lo llo bollom surfaco of llo concrolo.
CIoan llo loIo using comprossod air as llis is
nocossary for propor anclor porformanco.
IIaco llo vaslor and nul on llo anclor and pIaco
llo anclor inlo llo loIo so llal llo nul rosls soIidIy
againsl llo supporl baso pIalo. Tapping vill a lammor
may bo roquirod lo acliovo llis rosuIl.
Tigllon llo nul lo llroo lo fivo lurns pasl llo land-
ligll posilion.
4.4 Abanden in PIace
Damagod or corrodod boIl may bo Iofl in pIaco and
ono or sovoraI nov anclor loIos may bo driIIod inlo llo
baso pIalo and concrolo. Nov anclors may bo inslaIIod
in llo novIy proparod loIos according lo llo anclor
vondors inslaIIalion procoduro and nov vaslors and
nuls may bo pIacod and ligllonod lo compIolo llo ropair.
Wlon nov anclors aro pIacod cIoso lo llo oxisling
anclors, llo nul may bo romovod from llo abandonod
anclor, llus romoving llo lonsiIo Ioad from llal anclor
or llo abandonod anclor may bo cul off so as nol lo
inlorforo vill llo oquipmonl baso pIalo.
4.5 1eIerance en xpansien Ancher Lecatien
NOTI: Tloso may aIso bo appIiod lo adlosivo anclor Iocalions.
4.5.1 1eIerances Ier xpansien Ancher with 4.5
mbedment. Tlo Iocalion of an individuaI anclor may
bo clangod lo faciIilalo inslaIIalion, providod llo loIor-
ancos spocifiod in paras. 4.5.1.1 llrougl 4.5.1.3 aro mol.
4.5.1.1 RoIocalion of ono or lvo anclors villin
an arc as slovn in Iigs. 7 and 8 slaII bo pormissibIo if
llo foIIoving roquiromonls aro mol:
llo minimum odgo dislanco bolvoon llo anclor
and llo pIalo odgo mools llo roquiromonls of TabIo 1
roquiromonls of odgo dislanco, , and omboddod
Iongll, , por TabIo 2. Tloso loIorancos appIy in a silua-
lion vloro insload of driIIing a loIo in llo dosignalod
Iocalion, a loIo in llo aIlornalo Iocalion is driIIod.
4.5.1.2 Ixpansion anclors nol using llo loIor-
anco of para. 4.5.1.1 may bo roIocalod sucl llal llo spac-
ing is villin 3 mm (
1
8
in.) of llo spocifiod spacing for
M6 (
1
4
in.) and M10 (
7
16
in.) diamolor oxpansion anclor
and villin 6 mm (
1
4
in.) of llo spocifiod spacing for
M12 (
1
2
in.) and Iargor diamolor oxpansion anclors. Tlo
roquiromonls of TabIos 1 and 2 slaII appIy.
4.5.1.3 Ixpansion anclors nol mooling llo loIor-
ancos of paras. 4.5.1.1 and 4.5.1.2 slaII bo subjocl lo
an onginooring assossmonl by a slrucluraI onginoor for
rosoIulion on a caso-by-caso basis.

Fig. 7 keIecatien eI 0ne er 1we Anchers within an
Arc (
1
2
)

6FhFkAL hUTFS:
(a) Arc radlus
1
(b) X relccated anchcr

109
Fig. 8 keIecatien eI 0ne er 1we Anchers within an
Arc ( )

6FhFkAL hUTFS:
(a) Arc radlus
(b) X relccated anchcr

Fig. 9 keIecatien eI 0ne er 1we Anchers within a
esign PIate AssembIy

4.6 1eIerance Ier Anchers with 8 mbedment
Tlo Iocalion of an individuaI anclor may bo clangod
lo faciIilalo inslaIIalion, providod llo loIorancos spoci-
fiod in paras. 4.6.1 and 4.6.2 aro mol.
4.6.1 keIecatien eI 0ne er 1we Anchers within the
esign PIate AssembIy (Fig. 9). Tlo roIocalion of
anclors villin a circIo of radius slaII bo pormissibIo,
if llo roquiromonls of paras. 4.6.1.1 llrougl 4.6.1.4 aro
mol.
4.6.1.1 Tlo minimum odgo dislanco bolvoon llo
anclor and llo pIalo odgo mools llo roquiromonls as
slovn in TabIo 1.
4.6.1.2 Roquiromonls of and por TabIo 2.
4.6.1.3 If llo anguIarily of llo roIocalod anclor
is Ioss llan or oquaI lo 4 dog, uso of llo samo sizo anclor
is aIIovod.
4.6.1.4 If llo anguIarily of llo roIocalod anclor
is groalor llan 4 dog and Ioss llan 10 dog, llo noxl Iargor
sizo slaII bo usod for llo roIocalod anclor for oxampIo,
uso M16 (
5
8
in.) diamolor anclor in pIaco of M12 (
1
2
in.)
diamolor, M24 (1 in.) diamolor in pIaco of M20 (
3
4
in.)
diamolor. Ior oxisling M24 (1 in.) diamolor anclor, llo
roIocalod anclor slaII bo of llo samo diamolor if llo
anguIarily Iimilalion of 4 dog is salisfiod. BoIl anguIar-
ily is llo angIo off llo 90 dog porpondicuIar bolvoon
llo baso pIalo and llo anclor.
4.6.2 keIecatien eI Mere 1han 1we Anchers within
esign PIate AssembIy (Fig. 10). Any numbor of
anclors in a pIalo assombIy may bo roIocalod as Iong
as llo inslaIIod anclor spacing is villin pIus or minus
lvo boIl diamolors of llo dosignalod spacing and llo
roquiromonls givon in para. 4.6.1 aro mol. Ior ollor casos,
110
Fig. 10 keIecatien eI Mere 1han 1we Anchers
within a esign PIate AssembIy

onginooring slaII bo nolifiod for rosoIulion.
4.6.3 keIecatien eI Anchers 0utside the esign PIate
AssembIies (Fig. 11)
4.6.3.1 If ono boIl musl bo roIocalod bocauso of
inlorforonco, llo onliro rov of boIls slaII bo roIocalod
IiIoviso. Tlo maximum pormissibIo roIocalion slaII bo
75 mm (3 in.).
4.6.3.2 Roquiromonls of and por TabIo 2
and minimum odgo dislanco roquiromonls por TabIo 1
slaII bo mol.
4.6.3.3 A nov roclanguIar pI alo, or
vill a llicInoss of 6 mm (
1
4
in.) moro llan llo
oxisling assombIy pIalo slaII bo usod.
4.6.3.4 Allaclmonls slaII bo mado vill rospocl
lo llo nov pIalo assombIy conlorIino.
4.6.3.5 Anclors villin llo pIalo may bo
adjuslod in accordanco vill llo provisions in para. 4.5.
4.6.3.6 If moro llan ono rov of boIls las lo bo
roIocalod, an onginooring assossmonl slaII bo
porformod.
5 XAMIhA1I0h
Tlo llroadod rod oxlonsion voIdod por para. 4.1 slaII
bo oxaminod using llo magnolic parlicIo mollod por
ASMI BoiIor and Irossuro VossoI Codo, Soclion V.
Accoplanco/rojoclion criloria for MT aro llo appIicabIo
codo of conslruclion or llo posl-conslruclion codo. AII
ollor ropairs slaII bo oxaminod por originaI inslaIIalion

Fig. 11 bsing an nIarged PIate

roquiromonls and foIIov llo accoplanco criloria por llo

originaI inslaIIalion roquiromonls.
6 151IhC
Tosling slaII bo por originaI inslaIIalion roquiromonls.
In llo ovonl il is dolorminod llal losling of llo acluaI
ropairod anclor is nol foasibIo, il is accoplabIo lo ropro-
sonl llo inslaIIalion/ropair mollod in a prololypo if llo
anclor sampIo(s) aro proparod in llo samo mannor.
7 kFkhC5
ACI 318-02, BuiIding Codo Roquiromonls for SlrucluraI
Concrolo
IubIislor: Amorican Concrolo Inslilulo (ACI), 38800
Counlry CIub Drivo, Iarminglon HiIIs, MI 48331
111
ASMI BoiIor and Irossuro VossoI Codo, Soclion V,
D1.4, SlrucluraI WoIding Codo-Roinforcing SlooI
Io }ouno Road, Miami, II 33126
ManuaI of SlooI Conslruclion
IubIislor: Amorican Inslilulo of SlooI Conslruclion, Inc.
(AISC), Ono Iasl WacIor Drivo, Clicago, II
60601-1802

Anchers InstaIIatien bsing ChemicaI Means (Adhesive)
I-1 Adhesive Anchers
Adlosivo anclors lavo llo advanlago of vorIing in
Iovor slrongll concrolo, lovovor, lloy aro moro oxpon-
sivo lo inslaII llan moclanicaI anclors. Tlo adlosivo
anclor vorIs by driIIing a loIo in llo concrolo, fiIIing
il vill adlosivo, and llon insorling llo anclor. Tlo
sloar forco is sproad oquaIIy aIong llo Iongll of llo rod.
Tlo foIIoving aro Drop-In Adlosivo Anclor InslaIIalion
Inslruclions:
SoIocl llo propor sizo driII bil. DriII llo loIo por-
pondicuIar lo llo vorI surfaco. Do nol roam llo loIo
or aIIov llo driII lo vobbIo.
112
CIoan loIo of any dusl and dobris as any Iofl viII
roduco llo loIding capacily of llo anclor.
Injocl llo adlosivo inlo llo loIo approximaloIy
laIf fuII.
Insorl anclor inlo llo loIo vill a sIigll lvisling
molion.
AIIov llo adlosivo lo curo por llo manufacluros
spocificalion. Do nol loucl llo anclor during llis
curo limo.
Aflor llo curo limo las oIapsod, il is safo lo Ioad
llo anclor by pIacing a vaslor and nul on llo anclor
and ligllon lo lorquo vaIuos Iislod in llo manufaclurors
spocificalion.

ArticIe 3.9
vaIves with Pressure-5eaI-1ype ennets
113

ArticIe 3.10
het eIting
114

ArticIe 3.11
het and haII eIting kemevaI Precedures
1 5CkIP1I0h
1.1 Intreductien
BoIls in fIangod joinls vlicl lavo boon in sorvico can
bo difficuIl lo romovo. Sucl difficuIlios al llo slarl of
sluldovns for pIanl mainlonanco can rosuIl in coslIy
scloduIo inlorruplions, or oxlond llo duralion of aclivi-
lios invoIving somo lazard. Tlo uso of lol and laIf
boIling romovaI procoduros may bo considorod as a pos-
sibIo soIulion.
1.2 het eIting
is llo soquonliaI romovaI and ropIacomonl
of boIls on fIangod joinls vliIo undor roducod oporaling
prossuro (soo para. 3.4). Il is carriod oul ono boIl al a
limo in a prodolorminod cross pallorn soquonco. Iacl
ropIacod boIl is fuIIy lonsionod boforo llo noxl ono is
romovod.
Hol boIling can bo usod lo cIoan, Iubricalo, and
roinslaII oxisling boIls for pro-sluldovn aclivilios,
ropIaco corrodod or damagod boIls, or upgrado llo malo-
riaI spocificalion or grado of boIls.
NOTI: Hol boIling can aIso bo usod lo clocI rosiduaI boIl slross
aflor a poriod of oporalion, or lo roligllon Iooso boIls. Hol boIling
for lloso purposos is boyond llo scopo of llis Slandard.
1.3 haII eIting
is llo romovaI of ovory ollor boIl (so llo
fIango is Iofl vill laIf llo numbor of boIls) during pIanl
doprossurizalion, usuaIIy vlon llo syslom is cIoso lo
almosploric prossuro.
NOTI: HaIf boIling is aIso somolimos roforrod lo as sIip boIling
or odd boIling.
1.4 eIinitien eI eIt
as usod loroin is an aII-incIusivo lorm for any
lypo of llroadod faslonor llal can bo usod in a prossuro-
boundary boIlod fIango joinl assombIy sucl as a boIl,
slud, sludboIl, cap scrov, olc.
2 LIMI1A1I0h5
115
2.2 kisks Asseciated with het and haII eIting
AIllougl lol boIling and laIf boIling romovaI proco-
duros can roduco pIanl dovnlimo, lloy aro polonliaIIy
lazardous and lloroforo caulion slaII bo oxorcisod in
lloir pIanning and oxoculion. In considoring polonliaI
appIicalions for lol boIling and laIf boIling romovaI
procoduros, any polonliaI bonofils from lloso aclivilios
slouId bo carofuIIy voiglod againsl llo risIs (soo
para. 3.1).
2.2.1 kisks Asseciated with het eIting. Wlon con-
ducling lol boIling romovaI procoduros, llo risIs of fIuid
IoaIago aro incroasod duo lo incroasod boIling slrossos
and roIaxalion of gasIol comprossion, boll polonliaIIy
rosuIling in joinl IoaIago or gasIol sogmonl bIovoul.
2.2.2 kisks Asseciated with haII eIting. Wlon con-
ducling laIf boIling romovaI procoduros, llo risIs of
fIuid IoaIago aro incroasod duo lo roducod gasIol com-
prossionandllo possibiIily llal llo syslommayinadvor-
lonlIy bo ro-prossurizod. Ior llis roason, llo syslom
prossuro al vlicl laIf boIling is conduclod slouId bo
voII boIov dosign prossuro and proforabIy al or noar
almosploric prossuro vill IocaI managomonl conlroIs
in pIaco lo provonl ro-prossurizalion.
2.3 Precedures and 5aIe werk Practices
Tlo roquiromonls and guidanco for lol boIling and
laIf boIling romovaI providod in llis ArlicIo aro gonoric
in naluro and slaII bo combinod vill a job-spocific pro-
coduro aIong vill ollor approprialo pIanl safo vorI
praclicos.
3 5ICh
3.1 ngineering and kisk AnaIysis
An onginooring and risI anaIysis of llo proposod lol
boIling or laIf boIling romovaI oporalion slaII bo carriod
oul lo oslabIisl llal llo oporalion can bo porformod
safoIy, o.g., oslabIisl llal no unaccoplabIy ligl oxlornaI
Ioads and/or bonding momonls aro acling on llo joinl
llal couId causo IoaIago or gasIol bIovoul during llo
oporalion. Tlo anaIysis slouId considor, as a minimum,
llo foIIoving:
conlonls of llo piping or oquipmonl
dosign and oporaling prossuros and lomporaluros
possibIo upsol condilions
bonding momonl on joinl (soo para. 3.2.1)
(08)

posilion and funclionaIily of piping supporls
posilion and lypo of oxpansion boIIovs
mainlonanco lislory of llo joinl
oxporionco vill lol or laIf boIling procoduro
appIicalion lo simiIar joinls
llo largol lorquo usod in joinl assombIy
confinod vs. unconfinod gasIol lypo
NOTI: AspiraI vound gasIol vill a conloring ring is considorod
lo bo a confinod gasIol.
llrougl boIlod vs. boIls sluddod unlo lappod
loIos (soo para. 3.6)
gasIol maloriaI/llicInoss
condilion of fIango
condilion of boIls, incIuding considoral ion
vlollor llo nocossary boIl slross is sufficionl, or ovors-
lrossod (soo paras. 4.1.6 and 4.1.7)
condilion of nuls (soo paras. 4.1.6 and 4.1.7)
3.2 Minimum humber eI FIange eIts
UnIoss llo rosuIls of llo onginooring and risI anaIysis
oslabIisl llal llo consoquoncos of oillor joinl IoaIago
or gasIol bIovoul aro accoplabIo, fIangos slouId lavo
a minimum of oigll boIls.
3.2.1 ending Mements en A5M 16.5 CIass 150
FIanges. Tlo 8-boIl CIass 150 B16.5 fIango is rocognizod
as boing uniquoIy undor-boIlod and lloroby can onIy
accommodalo modosl oxlornaI bonding momonls, a con-
sidoralion in llo risI anaIysis.
3.3 etermining Maximum Pressures when
Cenducting het]haII eIting
Tlo maximum prossuro aIIovod vliIo conducling
oillor oporalion slaII laIo duo considoralion of
llo appIicabIo prossuro-coincidonl lomporaluro
raling, for slandard fIangos (sucl as ASMI 16.5 or
B16.47)
llo caIcuIalod maximum aIIovabIo prossuro por
llo appIicabIo codo of conslruclion, for nonslandard
fIangos
llo prosonco of oxlornaI Ioads and/or bonding
momonls on llo fIango and llo roIo lloy pIay on llo
fIango prossuro carrying capabiIily
NOTI: Il is rocommondod llal llo oxlornaI axiaI Ioads and oxlor-
naI bonding momonls acling across llo fIango bo consorvalivoIy
convorlod inlo oquivaIonl prossuro. Tlis lolaI oquivaIonl prossuro
pIus llo dosign prossuro of llo syslom undor considoralion
bocomos llo prossuro lo bo usod in llo risI anaIysis.
llo roduclion of offoclivo minimum gasIol com-
prossivo slross bolvoon boIls associal od vill boIl
romovaI, o.g., llal sufficionl Ioading romains on llo gas-
Iol lo onsuro llal il mainlains a soaI
3.4 Maximum Pressure]het eIting
UnIoss ollorviso juslifiod by an onginooring and risI
anaIysis, lol boIling may bo porformod onIy vlon llo
116
oporaling prossuro is oquaI lo or Ioss llan 50 of maxi-
mum prossuro aIIovod as dolorminod in para. 3.3.
3.4.1 CenIirming keduced Pressure Prier te het eIt-
ing. Confirmalion llal llo prossuro las boon roducod
and llal ro-prossurizalion is nol praclicabIo slaII bo
oblainod from oporalions porsonnoI boforo llo lol boIl-
ing romovaI oporalion is slarlod.
NOTI: In paras. 3.4.1 and 3.5.1, nol praclicabIo moans llal
sufficionl conlroIs aro in pIaco lo onsuro ro-prossurizalion viII nol
occur unliI llo syslomis rolurnod lo a slalus vlon il is safo lo do so.
3.5 Maximum Pressure]haII eIting
UnIoss ollorviso juslifiod by an onginooring and risI
anaIysis, laIf boIling may bo porformod onIy during
doprossurizalion vlon llo prossuro is oquaI lo or Ioss
llan 25of llo maximum aIIovabIo prossuro or 50 psig,
vliclovor is Iovor, and vlon Iov prossuro sloam, air,
or nilrogon (aIso soo para. 4.1.5) is llo purging modia.
NOTI: If llo fIuid conlonls aro sucl llal lloro is Iov risI of
injury associalod vill accidonlaI conlacl, llo nood for purging may
bo roviovod for doIolion.
3.5.1 CenIirming keduced Pressure Prier te haII eIt-
ing. Confirmalion llal llo prossuro las boon roducod
and llal roprossurizalion is nol praclicabIo slaII bo
oblainod from oporalions porsonnoI boforo llo laIf boIl-
ing romovaI oporalion is slarlod.
3.6 1apped heIes bse eI het eIting
If boIls slud inlo lappod loIos, llo uso of llo lol
boIling procoduro is nol rocommondod unIoss il is
Inovn llal llo llroads on llo sluddod ond of llo boIl
lavo boon roIiovod lo oIiminalo llo possibiIily of damag-
ing llo lappod llroads vlon llo boIl is bacIod oul.
Ivon if llis llroad roIiof las boon providod, il slouId
bo rocognizod llal sluddod joinls aro inloronlIy moro
sonsilivo lo roduclion in boIl proslross duo lo normaI
ombodmonl and gasIol croop offocls. AccordingIy, llo
probabiIily of a IoaI/gasIol bIovoul is groalor during
oillor a lol or laIf boIling oporalion llan for a counlor-
parl llrougl-boIlod joinl.
4 FAkICA1I0h
4.1 Preparatien
4.1.1 PersenneI Pretective quipment]mergency
PIanning. Approprialo proloclivo and safoly oquip-
monl slaII bo vorn in caso of IoaIago. Tlo nood for
omorgoncy slandby and conlingoncy pIanning slaII aIso
bo considorod.
4.1.2 Access Censideratiens. Considoralion slaII bo
givon lo llo accossibiIily of llo aroa and llal adoqualo
oscapo roulos aro avaiIabIo slouId unconlroIIod fIango
IoaIago occur.
4.1.3 Lecatien and Cenditien eI IseIatien vaIves.
Tlo Iocalion and condilion of llo noarosl upslroam and

dovnslroam isoIalion vaIvos slaII bo ascorlainod prior
lo commoncing vorI. Oporalions porsonnoI slaII lavo
a conlingoncy pIan for llo isoIalion of llo joinl, vlicl
addrossos llo nood lo bIocI in or doprossurizo llo oquip-
monl rapidIy slouId an unconlroIIabIo IoaI occur.
4.1.4 IdentiIicatien eI mergency FaciIities. As noc-
ossary, omorgoncy faciIilios sucl as safoly slovors and
oyo balls slouId bo idonlifiod and Iocalions mado
Inovn lo porsonnoI invoIvod in llo vorI.
4.1.5 Censideratien eI hitregen hazards. If nilrogon
is usod as a purging modium, considoralion slaII bo
givon lo proloclion of porsonnoI slouId a IoaI occur in
a confinod spaco.
4.1.6 Inspectien eI the FIange AssembIy. A llor-
ougl inspoclion of llo fIango assombIy slouId bo con-
duclodlo vorifyllo inlogrilyof llo fIango and ils boIling,
vill considoralion givon lo llo foIIoving:
dolorioralion of llo boIls and nuls, sucl as nocIing
(corrosion llinning), vorn llroads, or cracIing
llo abiIily of llo gasIol lo bo roligllonod and ils
bIovoul polonliaI
dolorioralion of llo gasIol, and llo polonliaI of
gasIol faiIuro duo lo dislurbanco or roliglloning
vorificalion of sufficionl llroad ongagomonl boforo
laIf boIling of sluddod fIangos, o.g., by uIlrasonic moa-
suromonl of slud Iongll
4.1.7 Assessment eI xisting eIt Lead CapabiIity.
If dolorioralion of boIls and nuls |soo para. 4.1.6(a)] is
found, considoralion slaII bo givon lo llo safoly aspocls
of boIl romovaI and llo incroasod Ioad on llo romaining
boIls. An anaIysis of llo minimum roquirod boIl Ioad
for IoaI ligllnoss and an assossmonl of llo possibIo boIl
slross may bo roquirod lo onsuro llo boIls lavo sufficionl
Ioad carrying capabiIily.
4.2 xecutien
4.2.1 Check eI xisting eIts Ier 1ightness. To anlic-
ipalo fIango boIl roIaxalion, ovory boIl slaII bo clocIod
for ligllnoss prior lo romoving llo firsl boIl. BoIl ligll-
noss may bo clocIod by appIying lorquo vill oillor a
land vroncl or a lydrauIic lorquo vroncl. Do nol uso
lammor (sIug) vronclos.
4.2.2 5equence eI eIt Changeeut. Wlon lol boIl-
ing, llo boIls slaII bo clangod oul ono al a limo in a
propor liglloning soquonco (soo TabIo 4 of
ASMI ICC-1). Tlo numboring syslom for llo appro-
prialo liglloning soquonco slouId bo marIod on llo
fIango in a roadiIy visibIo Iocalion boforo slarling lo
romovo any boIls.
4.2.3 Censideratiens keIative te In-service vs. Pre-
shutdewn. Tlo provisions of paras. 4.2.4 llrougl 4.2.7
may bo moro appIicabIo vlon llo fIango is inlondod lo
romain in sorvico, as opposod lo immodialoIy prior lo
117
sluldovn. Tlis slouId bo considorod in llo onginooring
and risI anaIysis (soo para. 3.1).
4.2.4 CIeaning and Lubricatien eI 5urIaces. As boIls
and nuls aro romovod, llo surfaco of llo fIangos vloro
conlacl is mado vill llo nuls slouId bo viro or povor
bruslod cIoan (romovo prolrusions, spol faco if
roquirod). Iropor Iubricalion vill an approvod Iubricanl
slouId bo appIiod lo llo friclion surfacos of llo boIl
assombIy. Tlis incIudos llo llroads and aII boaring sur-
facos of llo nuls oxcopl for llo surfaco bolvoon llo nul
and llo fIango al llo roar of llo joinl (on llo opposilo
sido of llo fIango from llo lorquo vroncl), vloro il is
bonoficiaI lo aIIov friclion lo dovoIop bolvoon llo boar-
ing surfacos.
4.2.5 hand 1ightening and aseIine eIt Length
keadings. InslaII boIls and nuls land ligll, vill llo
marIod onds of llo boIls and nuls Iocalod on llo samo
sido of llo joinl and facing oulvard lo faciIilalo inspoc-
lion. If uIlrasonic oIongalion conlroI is lo bo usod, iniliaI
boIl Iongll roadings slouId bo laIon and rocordod al
llis limo.
4.2.6 First Pass 1erquing. Boforo nov boIls/nuls
aro inslaIIod, clocI lo dolormino llal llo nuls run frooIy
by land pasl vloro lloy viII como lo rosl aflor ligll-
oning. If nuls viII nol lurn frooIy by land, clocI for
causo and maIo nocossary corroclions/ropIacomonls.
As oacl nov boIl is inslaIIod, ligllon llo boIl using
llo largol lorquo vaIuo. Conlinuo llis procoss for oacl
boIl in llo approprialo soquonliaI pallorn. If uIlrasonic
oIongalion conlroI is lo bo usod, roadings slouId bo
laIon aflor llo firsl oigll boIls lavo boon ropIacod, and
llo lorquo vaIuos adjuslod, if nocossary. If llo adjuslod
lorquo vaIuo is subslanliaIIy liglor llan llal usod for
llo firsl oigll boIls, lloso boIls slouId bo rolorquod
using llo nov lorquo vaIuo.
NOTI: DifforonliaI llormaI oxpansion may causo a Ioss of boIl
Ioad during llo cooIdovn of lol fIangos (soo para. 12 of
ASMI ICC-1). Tlis slouId bo considorod in dolormining llo lol
roassombIy boIl Ioad. In addilion, considoralion slouId bo givon
lo aIIoving ropIacomonl boIls lo roacl lloir oporaling lomporaluro
prior lo finaI liglloning.
4.2.7 FinaI 1erquing. Aflor oacl liglloning round,
laIo moasuromonls around llo circumforonco of llo gap
bolvoon fIangos vill a vornior or caIipor lo vorify llal
llo fIangos aro boing brougll logollor ovonIy (soo
para. 11.1 of ASMI ICC-1).
Aflor llo firsl pass lorquing aII boIls lo llo largol
lorquo vaIuo in an approprialo soquonliaI ordor, ono of
llo foIIoving aclions slaII bo roquirod, doponding upon
vlollor or nol uIlrasonic oIongalion conlroI is usod:
Tigllon aII boIls again using llo samo lorquo vaIuo
and foIIoving llo soquonliaI ordor from llo firsl pass,
foIIovod by ono or moro passos using llo largol lorquo
vaIuo in a rolalionaI ordor.

TaIo uIlrasonic roadings and adjusl llo lorquo
vaIuo, if nocossary. Tlon, if llo lorquo vaIuo is clangod
as a rosuIl of llo uIlrasonic oIongalion moasuromonls,
rolorquo lvico al llo finaI lorquo vaIuo in llo appro-
prialo soquonliaI ordor, foIIovod by al Ioasl ono pass in
a rolalionaI ordor, unliI llo nuls viII nol lurn al llo
largol lorquo. If il is nol nocossary lo clango llo largol
lorquo vaIuo, foIIov slop (a) abovo.
4.2.8 Cutting eI eIts. CoId culling of soizod boIls
and uso of nul spIillors is accoplabIo. TlormaI culling
mollods slouId nol bo porformod unIoss llo ongi-
nooring and risI anaIysis (soo para. 3.1) dolorminos llal
il can bo dono safoIy. Of parlicuIar concorn aro Iinos
conlaining conlonls llal can gonoralo a firo or roIoaso
loxic maloriaIs.
5 XAMIhA1I0h
5.1 xaminatien Ier werkmanship and Leakage
Willin llo conloxl of lloso roquiromonls, oxaminalion
consisls of an in-procoss visuaI clocI for goodvorIman-
slip and an in-sorvico visuaI clocI for signs of IoaIago.
118
5.2 xaminatien eI eIts Ier Preper MateriaI
5peciIicatien
Tlo marIings on llo boIls slouId bo visuaIIy clocIod
lo vorify llal llo corrocl maloriaI is boing usod. Tlis
may bo suppIomonlod vill IMI if addilionaI assuranco
of corrocl maloriaI is dosirod.
6 151IhC
Tloro aro no losling roquiromonls associalod vill llis
ArlicIo.
7 kFkhC5
ASMI B16.5, Iipo IIangos and IIangod Iillings, NIS
1-
1
2
Tlrougl NIS 24
ASMI B16.47, Iargo Diamolor SlooI IIangos, NIS 26
Tlrougl NIS 60
Box 2300, IairfioId, N} 07007-2300

ArticIe 3.12
Inspectien and kepair eI 5heII and 1ube heat xchangers
1 5CkIP1I0h
Tlis ArlicIo providos gonoraI good rocommondalions
and roquiromonls for llo foIIoving ropair loclniquos:
dolormining llo lypo of inspoclion loclniquo lo
uso for llo inspoclion of llo lubos and lubo bundIo of
a sloII and lubo loal oxclangor
dolormining llo lypo of inspoclion loclniquo lo
uso for llo inspoclion of llo luboslool and llo lubo-lo-
luboslool assombIy of a sloII and lubo loal oxclangor
dolormining llo lypo of inspoclion lo uso for llo
ollor prossuro conlaining compononls of a sloII and
lubo loal oxclangor
providing ropair loclniquos for common moclani-
caI faiIuros of various compononls in a loal oxclangor
2 LIMI1A1I0h5
2.1 CeneraI
2.2 xcIusiens
Tlis ArlicIo slaII nol bo appIiod lo loal oxclangors
conslruclod in accordanco vill ASMI BIVC
Soclion VIII, Division 3.
Hoal oxclangors ollor llan sloII and lubo dosign
aro nol incIudod in llo scopo of llis ArlicIo.
3 5ICh
Tlis soclion providos guidoIinos for considoralion
vlon dolormining ropairs lo compononls of loal
oxclangors. Il may bo nocossary for llo usor lo lavo
compIolod an inspoclion of llo compononls, considor
provious damago oxporioncod, or considor Iossons
Ioarnod in llo oporalion of simiIar oquipmonl prior lo
boginning dosign vorI.
3.1 xisting Cenditiens
Ixisling condilions aro as foIIovs:
llo originaI dosign condilions and caIcuIalions
onsuring llal llo dosign condilions, vill an
approprialo margin, corrospond lo llo acluaI normaI
oporaling modos incIuding slarlup, sluldovn, and
upsol condilions
curronl oporaling paramolors, i.o., prossuros, lom-
poraluros, clangos from normaI lo poaIing sorvico
119
dolorminalion if a prossuro and/or lomporaluro
roralo is roquirod.
dolorminalion if lloro is a nood for conducling
faiIuro anaIysis lo roduco llo polonliaI for fuluro dam-
ago. Roforonco aIso AII 579/ASMI IIS-1.
3.2 CeneraI
MaloriaIs usod for ropIacomonl compononls slaII
bo of llo samo maloriaI lypo as llo originaI compononl
unIoss an onginooring anaIysis is porformod indicaling
llo nood lo clango llo maloriaI duo lo llo damago mocl-
anism(s). Tlis anaIysis slaII accounl for nov mocla-
nisms inlroducod duo lo polonliaI maloriaI inloraclions.
Wlon soIocling llo maloriaI lo uso, llis anaIysis slaII
aIso considor llo nood lo malcl slrongll, louglnoss,
and I-numbor, and lo mool llo curronl louglnoss
roquiromonls of llo appIicabIo codo of conslruclion.
RopIacomonl compononls slaII bo of oquaI or
groalor llicInoss unIoss an onginooring anaIysis is por-
formod indicaling llo nood for a llicInoss Ioss llan llo
originaI compononl llicInoss.
Wlon considoring llo ropair mollod for lubos and
lubo bundIos, llo usor slaII considor llo impacl on llo
officioncy and ollor oporalionaI claraclorislics of llo
loal oxclangor duo lo llo polonliaI roduclion of loal
lransfor aroa. ConsuIlalion vill a loal lransfor spociaIisl
may bo nocossary.
Tlo foIIoving addil ionaI faclors slouId bo
considorod:
Dolorminalion of accoplabIo vaII Ioss viII
dopond on a numbor of faclors llal incIudo
duralion of curronl sorvico run
limo lo llo noxl pIannod oulago
llo crilicaIily of llo oxclangor oporalion
damago moclanisms llal llo lubos aro
oxposod lo incIuding llo ralo of corrosion
lisloricaI ralo of faiIuro and vlollor llal ralo
las boon incroasing
polonliaI for molaIIurgicaI upgrado
llo polonliaI consoquonco duo lo lubo faiIuro
oquipmonl accossibiIily
llo scopo of llo inspoclion vorI
llo accuracy and offoclivonoss of llo inspoc-
lion mollod
Ior loal oxclangors doomod crilicaI lo llo opor-
alion and/or procoss safoy of llo faciIily, llo foIIoving
slouId aIso bo considorod:
(08)

lolaI ropIacomonl of llo lubo bundIo vlon
lubos inspoclod indicalo a vaII Ioss of 40 or moro of
llo iniliaI, nominaI llicInoss
lubo bundIo ropIacomonl or individuaI lubo
ropIacomonl vlon lubos inspoclod indicalo a vaII Ioss
of 20 lo 40 of llo iniliaI, nominaI llicInoss
3.3 1ubes and 1ube undIes
Tubos and lubo bundIos slouId bo assossod using
llo dala oblainod by inspoclion porformod in accor-
danco vill Mandalory Appondix I for llo lypos of
ropairs lo porform, pIugging by voIdod, moclanicaI, or
friclion fil pIugs, parliaI ropIacomonl of llo lubo bundIo,
or fuII ropIacomonl of llo lubo bundIo.
Wlon considoring llo uso of moclanicaI or friclion
fil pIugs, llo usor slouId considor llo impacl on llo
officioncy and ollor oporalionaI claraclorislics of llo
loal oxclangor duo lo llo roduclion of loal lransfor
aroa, ospociaIIy for loal oxclangors llal aro doomod as
crilicaI lo llo oporalion and/or procoss safoly of llo
faciIily. ConsuIlalion vill a loal lransfor spociaIisl may
bo nocossary.
Tlo lubo bundIo supporls slouId bo assossod
using llo dala oblainod by inspoclion porformod in
accordanco vill Mandalory Appondix I. If dala indi-
calos llal faiIuro of lubos is duo lo damagod supporl
pIalos, considoralion slouId bo givon lo ropIacing vill
aIlornalivo dosigns. Spocific iloms lo considor incIudo
llo corrosion aIIovanco providod for llo sup-
porl pIalo slouId bo lvico llo vaIuo for llo sloII sido
duo lo llo polonliaI for llo pIalos lo corrodo al llo
rogions vloro llo lubos ponolralo llo supporls and Ioad
lo lubo virbralion inducod issuos. If zoro, considoralion
slouId bo givon lo assigning a nominaI vaIuo of 3 mm
(
1
8
in.).
considoralion slouId bo givon lo uso of aIIoy
supporl pIalos/baffIos insload of llicIor carbon slooI,
lovovor, lardor maloriaI may rosuIl in moro damago
lo llo lubos rallor llan llo supporl pIalos/baffIos. AIso,
llo offocls of difforonliaI llormaI oxpansion slouId bo
considorod. ConsuIlalion vill a maloriaIs/corrosions
spociaIisl may aIso bo nocossary.
llo spacing bolvoon llo supporl pIalos slouId
bo ovaIualod and adjuslod if anaIysis indicalos polonliaI
vibralion of lubos rosuIling in damagod lubos and/or
supporl pIalos. IvaIualion por TIMA RCB Soclion 5 and
Soclion 6 slouId bo considorod. ConsuIlalion vill a loal
lransfor spociaIisl may aIso bo nocossary.
If impingomonl proloclion is roquirod lo provonl
fIov-inducod orosion, rofor lo appIicabIo slandards sucl
as AII Slandard 660, TIMA, and HII for dosign
roquiromonls.
3.4 1ubesheet
MaloriaI usod lo ropIaco a luboslool slaII bo of
llo samo or groalor aIIovabIo slross as usod for llo
originaI compononl.
120
If an onginooring anaIysis indicalos lubo ropIaco-
monl of a Iargor diamolor is roquirod, addilionaI anaIysis
on llo luboslool slaII bo porformod lo dolormino if llo
Iigamonl officioncy is accoplabIo. Tlo anaIysis slaII mool
llo originaI codo of conslruclion, or if llis is nol Inovn,
llo anaIysis slaII mool llo roquiromonls of ASMI BIVC
Soclion VIII, Division 1.
Tuboslools slouId bo assossod using llo dala
oblainod by inspoclion porformod by a mollod Iislod
in Mandalory Appondix II for dolorminalion of ropair
or ropIacomonl of llo luboslool. Common condilions
for considoralion incIudo
cracIing (nol llrougl llo lolaI llicInoss) of
luboslool on sloII sido, moro lypicaI in vorlicaI unils.
InslaIIalion of a luboslool vonl and drain slouId bo
considorod lo promolo Iiquid fuII oporalion. Tlo vonl
slouId bo a 19 mm (
3
4
in.) nozzIo voIdod lo llo odgo
of llo luboslool, vill a 16 mm (
5
8
in.) loIo in llo lubo-
slool llal is paraIIoI lo llo lubos lo llo midsoclion of
llo luboslool, llon normaI lo llo lubos lo llo odgo of
llo luboslool. A galo or baII vaIvo slouId bo inslaIIod
on llo nozzIo aIong vill a bIind fIango or pIug.
soparalion of voId ovorIay cIadding rosuIling
from viro draving of ligl-prossuro lubosido fIuid IoaI-
ing llrougl lubo-lo-luboslool joinls.
cracIing in llo Iigamonl of llo luboslool. A
faiIuro anaIysis slouId bo porformod lo dolormino llo
damago moclanism. Tlo docision lo ropair vorsus
ropIaco llo luboslool slouId bo basod on llo damago
moclanism aIong vill llo oxlonl of llo Iigamonl
cracIing.
corrosion of llo luboslool can occur on llo bacI-
sido (sloII sido) of llo luboslool. Wlon llo corrosion
aIIovanco on llo bacIsido las boon consumod, llo lubo-
slool slouIdoillor bo ropIacod or an onginooring ovaIua-
lion porformod lo dolormino ils filnoss for sorvico.
corrosion of llo luboslool can occur on llo fronl
faco (lubo sido) of llo luboslool. Wlon llo corrosion
aIIovanco on llo faco las boon consumod, llo luboslool
slouId oillor bo ropIacod or an onginooring ovaIualion
porformod lo dolormino ils filnoss for sorvico. AIlorna-
livoIy, llo faco of llo luboslool may bo ropairod by voId
bui Idup llal is condil ionod by gri nding or ollor
moclanicaI moans sucl llal il is rolurnod lo llo originaI
llicInoss of llo luboslool. Iaclors lo considor vlon
pursuing llis oplion incIudo
minimum dislanco bolvoon llo fronl faco of
llo luboslool and llo groovo for lubo-lo-luboslool joinls
llo nood for voIding, slrongll or soaI, of llo
lubo-lo-luboslool joinl and llo nood for sol bacI from
llo fronl faco
3.5 1ube-te-1ubesheet [eints
Tubo-lo-luboslool joinls slouId bo assossod using llo
dala oblainod by inspoclion porformod by ono of llo
mollods Iislod in para. 5.3 for dolorminalion of ropair
lypo. Ropair lypos for IoaIing joinls incIudo

ropIacomonl of a damagod lubo, soo para. 4.4
pIugging a lubo, soo para. 4.2
romoving llo lubo and porforming voId buiIdup
of llo lubo loIo and llon romaclining llo lubo loIo lo
llo originaI lubo loIo diamolor. Dosign of llo moclanicaI
joinl slouId bo mado lo llo originaI codo of conslruclion,
an appIicabIo posl-conslruclion codo, or lo ASMI BIVC
Soclion VIII, Division 1, Appondix A. Caulion musl bo
oxorcisod lo avoid damago lo adjaconl lubos.
soaI voIding or slrongll voIding of llo joinl.
Dosign of llo voIdod joinl, if proviousIy voIdod, slouId
bo mado lo llo originaI codo of conslruclion, an appIica-
bIo posl-conslruclion codo, or lo ASMI BIVC Soclion
VIII, Division 1, Appondix A. Considoralion slouId bo
givon lo llo cIoanIinoss of llo joinl considoring polonliaI
rosiduo from llo fIuids.
considoralion slaII aIso bo givon lo llo offocl of
slyIo of loal oxclangor on Ioading of llo
lubo-lo-luboslool j oinl. Ior oxampIo, a fixod lubo
oxclangor may lavo liglor Ioadings duo lo difforonliaI
llormaI oxpansion llan a U-lubo oxclangor.
3.6 5heII, ChanneI, er 0ther Pressure-ketaining
Cempenents
MaloriaIs usod lo ropIaco or ropair prossuro-
rolaining porlions of a sloII or clannoI slaII bo of llo
samo aIIovabIo slross as llo originaI compononl, unIoss
addilionaI anaIysis is porformod lo juslify clanging llo
maloriaI.
RopIacomonl of lloso or ollor prossuro-rolaining
compononls slaII compIy vill llo appIicabIo codo of
conslruclion. Ior addilionaI guidanco on ropIacomonl,
soo ArlicIo 3.1.
Nonprossuro-rolaining porlions of compononls
slaII mool llo originaI conslruclion or appIicabIo
AddilionaI guidanco on pass-parlilion pIalos may
bo found in AII Slandard 660.
4 FAkICA1I0h
Wlon muIlipIo loal oxclangors aro in uso in a
paraIIoI configuralion, considoralion slouId bo givon lo
llo fIov roquiromonls for oacl oxclangor. Ixporionco
las slovn llal a singIo loal oxclangor romovod from
sorvico can rosuIl in liglor fIovs lo llo ollor loal
oxclangor(s) llal may causo damago from orosion, lubo
bundIo vibralions, or ollor moclanicaI damago.
Irior lo ropairs and lo incroaso accuracy of inspoc-
lion, llo lubos slouId bo ovaIualod for llo nood lo bo
cIoanod. CIoaning may bo porformod by ligl prossuro
valor bIasling, clomicaI soIulions, or abrasivo
bIasling/scrubbing. SoIoclionof a cIoaning mollodoIogy
slaII givo considoralion lo llo naluro of fouIing, lubo
maloriaI lypo, and lubo onlancomonls.
121
Higl prossuro valor bIasling is normaIIy por-
formod al 70 MIa (10,000 psi). In somo casos, uIlra-ligl
prossuro valor bIasling may bo nocossary al prossuros
up lo 275 MIa (40,000 psi). Ollor faclors ossonliaI lo
romovaI of doposils incIudo valor fIov ralo and llo
spray lip configuralion.
Wlon cIoaning vill clomicaI soIulions, a malo-
riaIs onginoor slouId bo consuIlod lo onsuro no dolri-
monlaI offocls occur lo llo lubos and/or sloII of llo loal
oxclangor. Ior oxampIo, a causlic soIulion slouId nol
bo usod in 300 sorios slainIoss slooI lubos.
Wlon porforming abrasivo bIasling/scrubbing,
caro slaII bo oxorcisod lo onsuro no advorso damago lo
llo lubos occurs. Dolorioralion of loal lransfor capabiIily
slaII bo considorod vlon cIoaning lubos vill inlornaI
compononls dosignod lo onlanco loal lransfor by
incroasing lurbuIonco llrougl llo lubos.
Inspoclion of llo lubos poriodicaIIy during llo
cIoaning procoss slouId bo mado lo onsuro consislonl
rosuIls. Uso of a boroscopo may improvo inspoclion
rosuIls.
Wlon a lubo bundIo musl bo romovod from ils
sloII for purposos of inspoclion or ropair, caulion slouId
bo oxorcisod lo avoid damago lo llo lubos or ollor
compononls.
Wlon il is Inovn llal a lubo or muIlipIo lubos
aro IoaIing, considoralion slaII bo givon lo puIIing a
lubo for faiIuro anaIysis lo aid in dolorminalion of llo
damago moclanism.
AII voIdod ropairs slaII bo mado using quaIifiod
voIding procoduros. WoIdors, and voIding oporalors
slaII bo quaIifiod in accordanco vill llo roquiromonls
of llo appIicabIo codo of conslruclion or llo appIicabIo
posl-conslruclion codo. WoIding procoduro quaIifica-
lions slaII incIudo impacl losls if roquirod by llo appIica-
bIo codo of conslruclion for llo compononl boing
ropairod.
WoIding maloriaIs and procossos slaII bo as cur-
ronlIy pormillod by llo appIicabIo codo of conslruclion
or posl-conslruclion codo for llo compononl. WoIding
of carbon and Iov aIIoy slooIs slouId bo porformod vill
Iov lydrogon oIoclrodos and procossos.
4.2 1ubeside kepair by PIugging
Ropair of lubos may bo accompIislod by pIugging
llo lubo al llo luboslool vill a voIdod or moclanicaI
allaclmonl.
AII lubos llal aro pIuggod slouId bo piorcod lo
provido for vonling and draining. Wlon doing so, vorli-
caI lubos slouId bo piorcod al oacl ond, and lorizonlaI
lubos slouId bo piorcod on lop and bollom of llo lubo.
Iiorcing of oacl lubo provonls possibIo pIug bIovoul
and pormils llo vaIidalion of llo inlogrily of llo lubo
pIug, soo para. 4.2(b)(4). Iargo lomporaluro difforonliaI
bolvoon lubosido and sloII sido may roquiro llo lubo
lo bo cul in lvo.

Fig. 1 1ypicaI Frictien Fit 1apered 1ube PIug
Iriclion fil laporod pIugs (Iig. 1) slaII onIy bo
usod in sorvicos llal mool aII of llo foIIoving condilions,
unIoss an onginooring ovaIualion is porformod indical-
ing llo accoplabiIily of lloso pIugs in ollor sorvicos:
sloII-sido oporaling prossuro 1.5 MIa (200 psi)
or Ioss
sloII-sido oporaling lomporaluro 205C (400I)
or Ioss
lubo-lo-luboslool joinls aro oxpandod and nol
voIdod
NOTI: Inspoclion of llo oxpandod lubo for lubo llinning slouId
bo mado lo onsuro llal inslaIIalion of llo pIug doos nol furllor
damago llo lubo Ioading lo soaI faiIuro bolvoon llo pIug and
llo lubos.
laporod pIugs llal aro inslaIIod vloro lubos aro
nol piorcod can prosonl a sorious safoly lazard. If llo
lubo cannol bo piorcod, llo lubo slouId bo puIIod or
ollor moasuros slouId bo laIon lo onsuro porsonnoI
proloclion, sucl as voIding llo pIug lo llo luboslool
and draining aII Iiquids from llo lubo boing pIuggod.
MoclanicaI pIugs (Iig. 2) slouId bo considorod
in silualions vloro friclion fil laporod pIugs aro nol
approprialo for llo prossuro and/or lomporaluro of sor-
vico or ollor moclanicaI/onvironmonlaI condilions.
Tloso lypos of pIugs lavo boon usod in sorvicos of up
lo 50 MIa (7,000 psi) and 595C (1,100I). MoclanicaI
pIugs aro lypicaIIy inslaIIod by a pnoumalic or lydrauIic
syslom. Soo Iig. 3. Ollor slyIos of pIugs may bo consid-
orod for liglor prossuros. Considoralion slaII aIso bo
givon lo llo foIIoving:
lubos vill inlornaI surfaco sovoroIy corrodod or
cracIod
vlon llo lubo and llo pIug lavo dissimiIar
molaIIurgy
inslaIIalion in sovoroIy corrosivo sorvico
condilion of llo moclanicaI joinl of llo lubo-
lo-luboslool in roIIod lubo silualions
122
A pIug map slouId bo dovoIopod lo rocord llo
numbor and Iocalion of lubos llal lavo boon pIuggod.
AddilionaIIy, llo numbor of lubos, cumuIalivo numbor
of lubos vorsus llo duralion, slouId bo clarlod. Wlon
llo slarp lurn in lubo faiIuro numbors occurs, ropIaco-
monl of llo lubo bundIo slouId bo considorod. Soo Iig. 4
for oxampIo clarl.
TracIing of prossuro Ioss duo lo lubo pIuggago
slouId bo considorod as somo oxclangor lypos cannol
funclion proporIy boyond corlain lubosido prossuro
Iossos. Irovisions for inlornaI bypass slouId bo consid-
orod if ropair is nol porformod in ordor lo provonl faiIuro
of pass parlilions. Iropor dosign of llis bypass can bo
dolorminod from induslry roforoncos in soclion 7 of llis
ArlicIo.
4.3 1ubeside kepair by PuIIing 1ubes
IuIIing llo lubo from llo oxclangor and pIugging
llo luboslool as doscribod in para. 4.2 slouId bo consid-
orod as a ropair oplion vlon pIugging is nol a viabIo
aIlornalivo, or vlon llo lubo viII bo rolainod for Iabora-
lory molaIIurgicaI anaIysis or ollor spocific oxaminalion.
Wlon puIIing a lubo and nol ropIacing, polonliaI
damago lo llo baffIo couId occur and considoralion lo
ropIacing llo lubo slouId bo mado. ConsuIlalion vill
a loal lransfor spociaIisl may aIso bo nocossary.
4.4 1ubeside kepair by kepIacement
Ropair may bo porformod by lubo ropIacomonl vlicl
may bo accompIislod in ono of llo foIIoving mollods:
ropIacing individuaI lubos, vlicl may incIudo
ropair/rofurbisling of llo luboslool in llo aroa of llo
subjocl lubo
ropIacomonl of llo onliro lubo bundIo. Soo
para. 3.2(c).
4.5 1ubesheet kepair
4.5.1 weId kepair eI Cracks
Ropair of gonoraI cracIs llal aro nol compIoloIy
llrougl llo llicInoss of llo luboslool and aro nol in
llo Iigamonls may bo mado in accordanco vill llo
guidoIinos of ArlicIo 3.4.
Ropair of gonoraI cracIs llal aro llrougl llo llicI-
noss of llo luboslool and nol in llo Iigamonls may bo
ropairod by proparing a U- or V-slapod groovo lo llo
fuII dopll and Iongll of llo cracI and llon fiIIing llo
groovo vill voId molaI in accordanco vill paras. 4.5.1
and 4.5.2.
Ropair of cracIs in llo Iigamonl aroa of llo lubo-
slool may bo mado in accordanco vill (a) or (b) abovo.
Considoralion may aIso bo givon lo porforming an ongi-
nooring anaIysis lo dolormino if llo oquipmonl may con-
linuo lo oporalo vill llo damagod luboslool. Tlis
anaIysis may bo porformod in accordanco vill
AII 579/ASMI IIS-1 or ollor posl-conslruclion
slandard.

Fig. 2 1ypicaI MechanicaI Fit 1ube PIugs
Fig. 3 1ypicaI InstaIIatien eI MechanicaI Fit 1ube
PIugs
w
123
Wlon maIing luboslool ropairs, considoralion
slouId bo givon lo llo impacl of llis ropair on llo lubos
in llo gonoraI aroa of llo ropair. Tlo foIIoving aclions
may bo nocossary:
romovaI of lubos in llo gonoraI aroa of llo ropair.
Soo para. 4.3(b).
ropair of llo lubo-lo-luboslool joinls.
4.5.2 Face kepair by 0verIay and Machining
GonoraI and IocaIizod llinning of luboslools may
bo ropairod by ovorIay voIding and romaclining of
llo faco.
Soo ArlicIo 2.2, for addilionaI iloms of
considoralion.
4.6 1ube-te-1ubesheet [eint kepair
4.6.1 keexpanding
CIoaning and inspoclion slaII bo porformod lo
dolormino llo condilion of llo lubo-lo-luboslool joinl
prior lo porforming llis lypo of ropair. Soo para. 4.1.
Tubo-lo-luboslool joinls vill IoaIs of a smaII fIov
ralo, ollorviso Inovn as vooping lubos, vloro no
apparonl damago las occurrod lo llo soaling surfacos,
may bo rooxpandod lo oblain an accoplabIo moclanicaI
fil of lubo lo luboslool. RoroIIing is ono accoplabIo
mollod of rooxpanding.
Irior lo rooxpanding, llo oxisling insido diamolor
of llo lubo in llo luboslool slaII bo dolorminod as voII
as llo Ioss of maloriaI duo lo corrosion/orosion. CaIcuIa-
lions for aIIovabIo maximum insido diamolor slaII bo
basod on moasurod fioId condilions, lubo proporlios,
and luboslool Iigamonl condilion.

Fig. 4 5ampIe Chart: humber eI 1ube FaiIures by Menth

Soo ASMI BIVC Soclion VIII, Division 1,
Appondix HH for addilionaI considoralions.
4.6.2 weId uiIdup kepair eI 1ube heIes and
Machining
Wlon a lubo is ropIacod and llo lubo loIo las
boon damagod, ropair may bo offoclod by voId buiIdup
and maclining of llo loIo.
AII voIdod lubo loIo ropairs slaII bo mado using
quaIifiod voIding procoduros. WoIdors, and voIding
oporalors slaII bo quaIifiod in accordanco vill llo
llo appIicabIo posl-conslruclion codo. WoIding proco-
duro quaIificalions slaII incIudo impacl losls if roquirod
by llo appIicabIo codo of conslruclion for llo luboslool.
or posl-conslruclion codo for llo luboslool. WoIding of
carbon and Iov aIIoy slooIs slouId bo porformod vill
Maclining of llo loIo slaII bo lo originaI manufac-
lurors spocificalions for diamolor and grooving.
4.6.3 5eaI weIding er 5trength weIding
Tubo-lo-luboslool voIds slaII bo in accordanco
If soaI voIds aro lo bo mado, considoralion slaII
bo givon lo llo moclanicaI lubo-lo-luboslool joinl lo
onsuro ils slrongll. If soaI voIds aro dolorminod lo bo
inadoqualo, llo voId slaII bo fuII slrongll lo onsuro llo
inlogrily of llo joinl.
AII voIds slaII bo mado using quaIifiod voIding
procoduros. WoIdors, and voIding oporalors slaII bo
quaIifiod in accordanco vill llo roquiromonls of llo
appIicabIo codo of conslruclion or llo appIicabIo
posl-conslruclion codo. WoIding procoduro quaIifica-
lions slaII incIudo impacl losls as roquirod by llo appIi-
cabIo codo of conslruclion for llo luboslool.
124
or posl-conslruclion codo for llo luboslool. WoIding of
carbon and Iov aIIoy slooIs slouId bo porformod vill
4.7 kepair eI Pressure Centainment Cempenents
Ropairs lo llo loal oxclangor sloII may bo porformod
lo llo originaI codo of conslruclion or appIicabIo
posl-conslruclion codo. Soo aIso ArlicIo 2.1 and
ArlicIo 2.2.
5 XAMIhA1I0h
Ixaminalion of loal oxclangors lypicaIIy covors llroo
aroas, oxlornaI, inlornaI, and lubo bundIo. Il is nol nocos-
sary for oacl inspoclion lo lavo llo samo froquoncy.
5.1 xaminatien eI 1ubes and 1ube undIe
Il is imporlanl for llo propor oxaminalion loclniquo
lo bo soIoclod for llo appIicalion al land. Tlo foIIoving
nondoslruclivo oxaminalion (NDI) loclniquos slouId
bo considorod for llo givon appIicalion. Soo aIso TabIo I-1
in Mandalory Appondix I for offoclivonoss of oxamina-
lion mollods. Ollor oxaminalion mollods may bo clo-
son by llo ovnor/oporalor, as foIIovs:
Iddy Curronl Ixaminalion (IT) is gonoraIIy
soIoclod for inspoclion of nonforromagnolic lubos, or
lloso llal aro sIigllIy magnolic. Nolo llal llo sonsilivily
of llis mollod docroasos for llo U-bond porlion of
U-lubo bundIos.
Romolo IioId Iddy Curronl (RIIT) is gonoraIIy
usodfor inspoclion of forromagnolic lubos. Ils sonsilivily
and accuracy may bo Ioss llan dosirod or roquirod and
viII roquiro a liglor numbor of lubos lo bo inspoclod.
Il is a quicIor mollod llan uIlrasonic mollods.
IarliaI Saluralion Iddy Curronl (ISIT) can Iocalo
and sizo cracIs in forromagnolic lubos. Il migll nol bo
sonsilivo lo O.D. dofocls.

Magnolic IIux IoaIago (MII) may aIso bo
soIoclod for inspoclion of forromagnolic lubos. Hovovor,
sonsilivily of llis mollod can bo poor for carbon slooI
lubos, and migll onIy bo bosl al dolormining llo ovoraII
condilion of llo lubo, nol dolormining individuaI dofocl
Iocalion.
UIlrasonic oxaminalion sysloms dosignod lo moa-
suro lubo vaII llicInoss may bo usod for smaII loal
oxclangors, vloro damago may bo IocaIizod, or for vaIi-
dalion of ollor NDI rosuIls. Tloso uIlrasonic oxamina-
lionsysloms aro parlicuIarIy suilod for carbonslooI lubos
duo lo llo IacI of sonsilivily of ollor NDI mollods.
Ono lypo of syslom is llo InlornaI Rolary UIlrasonic
Inspoclion (IRIS) syslom. IRIS is an accuralo NDI
mollod for dolocling and sizing I.D. and O.D. molaI
Ioss in lubos. Anollor lypo of syslom is Sloar Wavo IRIS
(SWIRIS) and llis can bo offoclivo for dolocling I.D. and
O.D. cracIs. Boll IRIS and SWIRIS roquiro cIoan lubos.
Ollor NDI mollods may bo moro approprialo for
llo inspoclion. Considoralion slouId bo givon lo llo uso
of radiograply (RT) or vidoo probo inspoclion. Tloso
mollods may bo bollor suilod for inspoclion of llo
U-bond porlion of U-lubo bundIos.
Considoralion slouId bo givon lo llo moniloring
and lronding of lubo condilion as parl of a prodiclivo
mainlonanco and/or ropIacomonl program.
Tlo minimum numbor of lubos lo bo inspoclod
may bo dolorminod by llo mollods providod in
Mandalory Appondix I.
5.2 xaminatien eI 1ube-te-1ubesheet kepair
Ropairs slaII bo oxaminod by ono or moro of llo foI-
Ioving mollods:
prossuro or IoaI losling on llo sloII sido, soo
soclion 6
Iiquid ponolranl oxaminalion (IT) in accordanco
posl-conslruclion codo
visuaI oxaminalion (VT) in accordanco vill ASMI
BIVC Soclion V, ArlicIo 9
5.3 xaminatien eI 1ubesheet kepair
VT in-procoss voId oxaminalion slaII bo
porformod.
Surfaco oxaminalion by IT slaII bo porformod al
llo compIolion of llo voId ropair.
VoIumolric oxaminalion by UT slouId bo consid-
orod vlon lloro is a possibiIily of addilionaI fIavs boing
inlroducod lo llo luboslool during llo ropair.
5.4 xaminatien eI Pressure Centainment
Cempenents kepairs
AII voIdod ropairs slouId rocoivo VT and IT or
MT oxaminalion, ospociaIIy for loal oxclangors doomod
crilicaI lo llo oporalion and/or procoss safoly of llo
faciIily.
125
Wloro possibIo, voIdod ropairs slaII rocoivo voIu-
molric oxaminalion by RT or UT.
6 151IhC
IoIIoving compIolionof llo inspoclion, a prossuro losl
or ligllnoss losl in accordanco vill ArlicIo 5.1 slouId bo
considorod, parlicuIarIy if llo inlogrily of llo
lubo-lo-luboslool joinl is in quoslion.
7 kFkhC5
AII Slandard 660, SloII and Tubo Hoal Ixclangors for
GonoraI Rofinory Sorvicos, 2003 Idilion
AII RI 579/ASMI IIS-1, Iilnoss-Ior-Sorvico, 2nd
Idilion, 2007
Soclion V Nondoslruclivo Ixaminalion
Irossuro VossoIs
ASMI ICC-2, Ropair of Irossuro Iquipmonl and Iiping
ASMI ICC-3, Inspoclion IIanning Using RisI Basod
Mollods
Inginoors (ASMI). Tlroo IarI Avonuo, Nov YorI,
Box 2300, IairfioId, N} 07007-2300
ASTM I 2283-03, Slandard Iraclico for Ixlromo VaIuo
AnaIysis of NonmolaIIic IncIusions in SlooI and Ollor
MicroslrucluraI Ioaluros
Drivo, I.O. Box C700, Wosl ConslolocIon, IA
19428-2959
WoIf, GoraId M. and Adams, Roborl B., An Improvod
IIugging Syslom for HX Tubing, IIRI BIO
Conforonco papor, }uno 1996
IubIislor: Tlo IIoclric Iovor Rosoarcl Inslilulo (IIRI),
3412 HiIviov Avonuo, IaIo AIlo, CA 94304
Slandards for Iovor IIanl Hoal Ixclangors, 4ll
Idilion, 2004
Slandards for CIosod Ioodvalor Hoalor, 7ll Idilion,
2004
IubIislor: Hoal Ixclango Inslilulo, Inc. (HII), 1300
Summor Avonuo, CIovoIand, OH 44115-2815
Slandards of llo TubuIar Ixclangor Manufaclurors
Associalion, Iiglll Idilion
IubIislor: TubuIar Ixclangor Manufaclurors
Associalion, Inc. (TIMA), 25 Norll Broadvay,
Tarrylovn, NY 10591

Androono, CarI I. and YoIoII, S., TubuIar Hoal Ixclangor
Inspoclion, Mainlonanco and Ropair, McGrav-HiII,
Nov YorI, NY, 1997.
Wang, W. David, Il.D., Ixlromo VaIuo AnaIysis of Hoal
Ixclangor Tubo Inspoclion Dala, Irocoodings of
126
IVI2006-ICIVT-11, 2006 ASMI Irossuro VossoIs and
Iiping Division Conforonco, }uIy 2006.
Bypass-caIcuIalion-R3.xIs, lllp://vvv.mgl-inc.com/
docs/Bypass-caIcuIalion-R3.xIs.

Metheds Ier etermining Minimum humber eI 1ubes te
Inspect
I-1 Intreductien
Tlis Appondix providos gonoraI good rocommonda-
lions and roquiromonls for dolormining llo numbor of
lubos lo inspocl by difforonl mollods. Tlo usor may
soIocl any mollod, and may aIso dovialo fromllo rocom-
mondalions and roquiromonls of oacl mollod basod on
llo roquiromonls of llo loal oxclangor.
I-1.1 Fixed 1ube Ceunt
Tlo foIIoving minimum numbor of lubos inspoclod
slouId bo considorod:
50 lubos or 25 of lubo lolaI, vliclovor is groalor,
for loal oxclangors vill a lolaI lubo counl of Ioss llan
500 lubos.
20 of lubo lolaI for loal oxclangors vill a lolaI
lubo counl of 500 lubos or moro, up lo 750 lubos.
lubo counl of 750 lubos or moro, up lo 1,000 lubos.
lubo counl of moro llan 1,000 lubos.
I-1.2 1ube undIe
Tlo foIIoving aroas of llo lubo bundIo slouId bo
oxaminod al a minimum:
llo firsl llroo rovs adjaconl lo llo inIol nozzIo and
llo Iasl lvo rovs adjaconl lo llo oxil nozzIo.
ovory socond lubo around llo porimolor of llo
bundIo. Ior muIlipass loal oxclangors, llo porimolor
of oacl pass slaII bo incIudod.
a soIoclion of lubos in llo inlorior soclion of llo
bundIo.
aroas vill a lisloryof aclivo damago moclanisms.
aroas llal lavo nol proviousIy boon oxaminod.
faiIuro of 10 of llo lubos oxaminod slaII roquiro
an addilionaI 10 of lubos lo bo oxaminod in llo oxam-
inod aroa, as por (a) llrougl (o).
127
I-1.3 bse eI Inspectien PIanning
An inspoclion pIanning program may bo impIo-
monlod lo dolormino llo numbor of lubos lo inspocl and
llo froquoncy al vlicl llo lubos slaII bo inspoclod.
Irogram impIomonlalion guidoIinos aro providod
in ASMI ICC-3. Tlo foIIoving faclors slouId bo
considorod:
inspoclion offoclivonoss roquirod, soo TabIo I-1
for various offoclivonoss and llo associalod mollods of
inspoclion.
maximum inspoclion inlorvaI pormillod.
lypo of inspoclion roquirod for llo suspoclod
damago moclanism. Soo TabIo I-1 for addilionaI dolaiIs.
inspoclion mollods (soo para. 5.1)
I-1.4 bse eI xtreme vaIue AnaIysis (vA)
Uso of IVA maIos il possibIo lo accuraloIy assoss
llo romaining Iifo of Iargo numbors of lubos using roIa-
livoIy minimaI dala.
IVA assossmonl is basod on ASTM I 2283, Slan-
dard Iraclico for Ixlromo VaIuo AnaIysis of NonmolaIIic
IncIusions in SlooI and Ollor MicroslrucluraI Ioaluros.
Uso of IVA lo assoss llo maximum vaII Ioss dala
las boon doscribod in conforonco pubIicalions, soo
TabIo I-1, Nolo (4).
Tlo IVA mollod and rosuIls may bo incorporalod
inlo an inspoclion pIanning assossmonl.
Will smaIIor sampIo sizos, idoaIIy 20 lo 30 lubos
rogardIoss of llo numbor of lubos in llo oxclangor, llo
approprialo inspoclion offoclivonoss may bo acliovod
by using llo Iovor bound vaIuo of 99, 95, 90, and
80 confidonco inlorvaIs.

1abIe I-1 Inspectien IIectiveness 1abIe

Flghly effectlve wall lcss lklS
(2)
80% tc 100% 80% tc 100% hct appllcable
|excludlng MlC
(1)
[
. . . lklS and FvA
(3)
20 tc 30 20 tc 30 . . .
99% Cl as
lcwer bcund
. . . kFFT
(/)
cr MFL
(5)
100% and pull hct appllcable . . .
2 wcrst tubes
fcr lab analysls
. . . FT
(6)
hct appllcable 100% . . .
Cracklng SwlklS
(7)
100% hct appllcable . . .
Cracklng cr MlC FT hct appllcable 100% . . .
usually effectlve wall lcss cr lklS 60% tc 80% 60% tc 80% Prcflle kT 50%
lccallzed and at 0 deg and
general ccrrcslcn 90 deg
(excludlng MlC)
. . . lklS and FvA 20 tc 30 20 tc 30 . . .
95% Cl as
lcwer bcund
. . . kFFT cr MFL 100% and use hct appllcable . . .
lklS cn 2
wcrst tubes
PSFT
(8)
90% hct appllcable . . .
. . . FC hct appllcable 80% . . .
Cracklng SwlklS 80% hct appllcable . . .
. . . PSFT 100% hct appllcable . . .
Cracklng cr MlC FC hct appllcable 80% . . .
Falrly effectlve wall lcss lklS /0% tc 60% /0% tc 60% hct appllcable
(excludlng MlC)
. . . lklS and FvA 20 tc 30 20 tc 30 . . .
90% Cl as
lcwer bcund
128

1abIe I-1 Inspectien IIectiveness 1abIe (Cent'd)

lklS cn 2
wcrst tubes
PSFT 70% hct appllcable . . .
. . . FC hct appllcable 60% . . .
Cracklng SwlklS 60% hct appllcable . . .
. . . kFFT cr MFL 100% . . . . . .
Pccrly effectlve wall lcss lklS 20% tc /0% 20% tc /0% hct appllcable
(excludlng MlC)
. . . lklS and FvA 20 tc 30 20 tc 30 . . .
80% Cl as
lcwer bcund
lklS cn 2
wcrst tubes
PSFT 50% hct appllcable . . .
. . . FC hct appllcable /0% . . .
Cracklng SwlklS /0% hct appllcable . . .
. . . kFFT cr MFL 80% . . . . . .
hUTFS:
(1) MlC mlcrcblclcglcaly lnduced ccrrcslcn
(2) lklS lnternal rctary lnspectlcn system
(3) FvA extreme value analysls
(/) kFFT remcte fleld eddy current
(5) MFL magnetlc flux leakage
(6) FT eddy current testlng
(7) SwlklS shear wave lnternal rctary lnspectlcn system
(8) PSFT partlal saturatlcn eddy current
129

xaminatien eI Pressure Centainment Cempenents
II-1 XAMIhA1I0h
Ixaminalion of llo sloII, clannoI, and ollor prossuro
conlainmonl compononls, oxcIuding llo lubos, may bo
porformod by any of llo foIIoving mollods:
RT
UT
MT
VT
inlornaI inspoclion by romovaI of lubo bundIo
inlornaI inspoclion by romolo camora or ollor
inspoclion probo inslrumonl
130
II-2 Ih5PC1I0h
Tlo inspoclion of lloso compononls slouId occur con-
curronlIy vill llo inspoclion of llo lubos.
II-3 5bI1AILI1
Irossuro conlainmonl compononls aro parlicuIarIy
suil od for inspoclion pIanning mollods sucl as
doscribod by ASMI ICC-3.
(08)

PAk1 4
h0hM1ALLIC Ah 0h kPAIk5
ArticIe 4.1
henmetaIIic Cempesite kepair 5ystems Ier PipeIines and
Pipewerk: high-kisk AppIicatiens
1 5CkIP1I0h
1.1 5cepe
Tlis ArlicIo providos llo roquiromonls for llo ropair of
pipovorIand pipoIinos using a quaIifiod Ropair Syslom.
Tlo Ropair Syslom is dofinod as llo combinalion of
llo foIIoving oIomonls for vlicl quaIificalion losling
las boon compIolod:
subslralo (pipo)
surfaco proparalion
composilo maloriaI (ropair Iaminalo)
fiIIor maloriaI
adlosivo
appIicalion mollod
curing prolocoI
Tlo composilo maloriaIs aIIovod for llo Ropair
Syslom incIudo, bul aro nol Iimilod lo, gIass, aramid, or
carbon fibor roinforcomonl in a llormosol poIymor (o.g.,
poIyoslor, poIyurollano, plonoIic, vinyI oslor, or opoxy)
malrix. Iibors slaII bo conlinuous.
1.2 AppIicabiIity
Tlis ArlicIo addrossos llo ropair of pipovorI and
pipoIinos originaIIy dosignod in accordanco vill a vari-
oly of pipo slandards, incIuding ASMI B31.1/B31.3/
B31.4/B31.8, and ISO 15649 and 13623.
Tlo Ropair Syslom quaIificalion, dosign, inslaIIalion,
and oporalionaI roquiromonls providod in llis ArlicIo
covors silualions invoIving damago commonIy oncoun-
lorod in piping sysloms.
Tlo foIIoving lypo of dofocls may bo ropairod (and
aro assossod in para. 3.3.3):
oxlornaI corrosion vloro slrucluraI inlogrily is
compromisod. In llis caso il is probabIo llo appIicalion
of a Ropair Syslom viII arrosl furllor dolorioralion.
oxlornaI damago sucl as donls, gougos, frolling,
or voar (al supporls).
131
cracIs may bo ropairod in accordanco vill llis
ArlicIo if lloy aro proparod in accordanco vill ArlicIo
3.4.
oillor inlornaI corrosion or orosion, or boll, vlicl
may or may nol bo IoaIing. In llis caso, il is probabIo
llal corrosion viII conlinuo and llo assossmonl musl
laIo llis inlo accounl.
IoaIs.
manufacluring or fabricalion dofocls.
InlornaI fIuids andoxlornaI onvironmonls slaII bo con-
sidorod vill rospocl lo compalibiIily of llo composilo.
Tlo prossuro/lomporaluro Iimils aro dopondonl on llo
lypo of damago boing ropairod and llo Ropair Syslom
boing usod. Tloso Iimils aro dolorminod by llo losling
and quaIificalion roquiromonls of llis ArlicIo. A Iovor
unIoss a Iovor lomporaluro capabiIily is domonslralod
llrougl quaIificalion losling.
Tlis ArlicIo appIios lo ropairs lo boll molaIIic and
nonmolaIIic (subslralo) pipo maloriaIs.
1.3 kisk Assessment
An assossmonl of llo risIs associalod vill llo dofocl
and ropair mollod slaII bo compIolod in Iino vill llo
roIovanl induslry bosl praclico. Wlon appIying a Ropair
Syslom in accordanco vill llis ArlicIo llo foIIoving
iloms slaII bo considorod:
assossmonl of llo naluro and Iocalionof llo dofocls
dosign and oporaling condilions for llo pipo and
conlonls (incIuding prossuro, lomporaluro, sizos, and
combinalions lloroof)
ropair Iifo (soo para. 1.4)
goomolry of llo pipo boing ropairod
lazards associalod vill syslom sorvico
llo avaiIabiIily of llo porsonnoI vill llo nocos-
sary sIiIIs
(08)
(08)

llo oaso vill vlicl il is praclicabIo lo oxoculo
surfaco proparalion oporalions
porformanco undor upsol and major incidonl silu-
alions incIuding impacl, abrasion, firo, oxpIosion, coIIi-
sion, and onvironmonlaI Ioading
faiIuro modos
inspoclabiIily
llo Ropair Syslom maloriaIs
Tlo informalion and dala doscribing any lazards
slaII bo incIudod in llo mollod slalomonl (para. 4.4) lo
bo usod on silo.
Tlo appIicalion of lloso Ropair Sysloms viII lypicaIIy
clango llo modo of faiIuro from rupluro lo a IoaI, llo
consoquoncos of faiIuro viII lloroforo bo roducod. A
ropair appIiod in accordanco vill llis ArlicIo viII aIso
roduco llo probabiIily of faiIuro.
1.4 kepair LiIe
Tlo ropair Iifo is llo usofuI sorvico poriod of llo Ropair
Syslom, as dofinod by llo dosign assossmonl. Tlis may
bo Iimilod by llo dofocl lypo and sorvico condilions
(o.g., inlornaI corrosion). Tlo ropair Iifo viII dopond on
llo Ropair Syslom.
1.5 eIect Assessment
Dofocl assossmonl in llo losl pipo slaII bo porformod
vill llo provaiIing slandard, o.g., ASMI B31G, AII
579/ASMI IIS-1, BS 7910, or oquivaIonl.
2 LIMI1A1I0h5
2.2 uaIiIicatien
Tlo uso of llis ArlicIo is Iimilod lo lloso Ropair Sys-
loms for vlicl llo quaIificalion losling doscribod in
Mandalory Appondix II las boon compIol od. Any
clango lo any oIomonl of llo Ropair Syslom (soo para.
1.1) conslilulos a difforonl and lloroforo nov Ropair
Syslom. Tlis nov Ropair Syslom slaII roquiro quaIifica-
lion as doscribod in Mandalory Appondix II. Soo aIso
para. 3.6. Tlo Ropair Syslom suppIior slaII slalo llo lypo
of dofocls (as Iislod on llo Guido for SoIoclion) lo vlicl
lloir Ropair Syslom las boon quaIifiod againsl.
2.3 InstaIIatien
Tlo inslaIIalion procoduros slaII bo lloso usod in llo
Ropair Syslom quaIificalion. If llo inslaIIalion proco-
duros aro nol lloso usod in llo Ropair Syslom quaIifica-
lion, llon llo ropair is nol in compIianco vill llis
ArlicIo.
132
3 5ICh
3.1 5ymbeIs
Tloso aro llo symboIs usod llrougloul llis ArlicIo.
oxlornaI pipo diamolor, m (in.)
diamolor (or diamolor of llo oquivaIonl cir-
cIo) of llo dofocl or IoaIing rogion, m (in.)
bonding moduIus for llo composilo Iami-
nalo dolorminod by losl according lo TabIo 1,
N/m
2
(psi)
lonsiIo moduIus for llo composilo Iaminalo

in llo axiaI diroclion dolorminod by losl
according lo TabIo 1, N/m
2
(psi)

in llo circumforonliaI diroclion dolorminod
by losl according lo TabIo 1, N/m
2
(psi)
lonsiIo moduIus for slooI (or pipo maloriaI),

N/m
2
(psi)
sum axiaI lonsiIo Ioads duo lo prossuro,
bonding, and axiaI llrusl, N (Ib). Nolo llal
llo axiaI lonsiIo Ioad gonoral od by an
appIiod bonding momonl is (4/)
sorvico faclor from TabIo 4
cycIic doraling faclor
lomporaluro doraling faclor

sloar moduIus for llo composilo Iaminalo,
N/m
2
(psi)
accoIoralion of gravily, 9.81 m/s
2
(384 in./
soc
2
)
loal dislorlion lomporaluro, C (I)
buriod dopll of pipoIino, m (in.)
lolaI axiaI ropair Iongll, m (in.)
dofocl
axiaI Iongll of llo dofocl, mm (in.)
ovor
ovorIap Iongll, m (in.)
lapor
lapor Iongll, m (in.)
axiaI Iongll of dofocl, m (in.), lo bo usod in
losl spocifiod in Mandalory Appondix III
appIiod bonding momonl, Nm (Ib-in.)
numbor of cycIos
numbor of vraps
inlornaI dosign prossuro, N/m
2
(psi)
appIiod oxlornaI prossuro, N/m

2
(psi)
oxl,soiI
oxlornaI soiI prossuro, N/m
2
(psi)
faiIuro prossuro of llo undamagod pipo,

N/m
2
(psi)
Iivo
inlornaI prossuro villin llo pipo during
appIicalion of llo ropair, N/m
2
(psi)
max
maximum inlornaI prossuro of llo prossuro
cycIo, N/m
2
(psi)
min
minimum inlornaI prossuro of llo prossuro
cycIo, N/m
2
(psi)
MAWI for llo pipo vill llo dofocl dolor-

minod from AII 579, ASMI B31G, or oquiv-
aIonl, N/m
2
(psi), incIuding considoralion
of fuluro corrosion aIIovanco
losl
losl prossuro, N/m
2
(psi)
(08)

cycIic Ioading sovorily, dofinod as:

min
/
max
SMYS (Spocifiod Minimum YioId Slrongll
doralod as roquirod by llo approprialo con-
slruclion codo) of pipo, N/m
2
(psi)
moasurod yioId slrongll of slooI pipo or miII

corlificalion, N/m
2
(psi)
claraclorislic lonsiIo slrongll of composilo

in circumforonliaI (loop) diroclion, vloro
llo claraclorislic slrongll is oquaI lo llo
moan slrongll minus lvo slandard dovia-
lions, N/m
2
(psi)
95 Iovor confidonco Iimil of llo Iong-lorm

slrongll dolorminod by porformanco losling
in accordanco vill Mandalory Appondix II,
N/m
2
(psi)
dosign lomporaluro of Ropair Syslom, C

(I)
gIass lransilion lomporaluro, C (I)
uppor lomporaluro Iimil of Ropair Syslom,

C (I)
nominaI vaII llicInoss of originaI pipo,
m (in.)
Iayor
pIy or Iayor llicInoss of llo composilo
ropair maloriaI, m (in.)
min
minimum ropair llicInoss, m (in.)
ropair
dosign ropair llicInoss, m (in.)
minimum romaining vaII llicInoss of llo

pipo, m (in.)
vidll of sIol dofocl, m (in.)
vidll of dofocl in loop diroclion lo bo usod
in losl spocifiod in Mandalory Appondix III,
m (in.)
llormaI oxpansion coofficionl of llo ropair

Iaminalo in llo axiaI diroclion by dolor-
minod losl in accordanco vill TabIo 1, C
-1
(I
-1
)
llormaI oxpansion coofficionl of llo ropair

Iaminalo in llo circumforonliaI diroclion by
dolorminod losl in accordanco vill TabIo 1,
C
-1
(I
-1
)
llormaI oxpansion coofficionl of llo sub-

slralo or originaI pipo, C
-1
(I
-1
)
louglnoss paramolor (onorgy roIoaso ralo)
for llo composilo pipo inlorfaco moa-
surod according lo Mandalory Appondix IV,
}/m
2
(in.-Ib/in.
2
)
soiI
spocific soiI donsily, Ig/m
3
(Ib/in.
3
) |in
absonco of dala assumo

2 000 Ig/m
3
(0.072 Ib/in.
3
)]
lomporaluro difforonco (absoIulo) bolvoon
oporalion and inslaIIalion, C (I)
aIIovabIo axiaI slrain oblainod from oq. (9)
aIIovabIo circumforonliaI slrain oblainod

from oq. (9)
0
aIIovabIo axiaI slrain oblainod from TabIo 3
133
0
aIIovabIo circumforonliaI slrain oblainod
from TabIo 3
llormaI slrain
Iap sloar slrongll, N/m
2
(psi)
Ioissons ralio for llo composilo Iaminalo

in llo circumforonliaI diroclion (Ioad in cir-
cumforonliaI diroclion, conlraclion in axiaI
diroclion) dolorminod by losl according lo
TabIo 1
3.2 kepair 5ystem uaIiIicatien ata
QuaIificalion of llo Ropair Syslom slaII bo compIolod
in accordanco vill TabIo 1 and Mandalory Appondix II.
IquivaIonl nalionaI or inlornalionaI pubIislod losl
mollods aro aIso accoplabIo.
MaloriaIs porformanco and losl dala slaII bo moa-
surod by a corlifiod or nalionaIIy accrodilod losl faciIily,
or corlifiod by a rogislorod IrofossionaI Inginoor (or
inlornalionaI oquivaIonl).
Ropair Syslom quaIificalion dala slaII bo moasurod
for oacl famiIy of molaI subslralos (o.g., carbon slooI,
Iov- and ligl-aIIoy slooI, slainIoss slooI, olc.).
3.2.1 asic MateriaI ecumentatien. Tlis slaII
incIudo a slalomonl of llo poIymor sysloms, incIuding
roinforcomonls usod, and any slandards lo vlicl lloy
aro suppIiod. Basic dala on maloriaI compalibiIily vill
llo vorIing onvironmonl slaII aIso bo avaiIabIo. Il slaII
bo onsurod llal any clomicaI inloraclion bolvoon llo
composilo and pipo viII nol causo furllor dogradalion
in llo surfaco of llo pipo. Considoralion may nood lo
bo givon lo llo offocls of llo poIymor sysloms and lloir
associalod curing agonls. IarlicuIar allonlion may nood
lo bo givon lo CIRI Iaminalos and llo polonliaI for
bimolaIIic (gaIvanic) corrosion of llo losl pipo.
3.2.2 5urIace Preparatien. Tlo durabiIily of a
bondod assombIy undor appIiod Ioad is dolorminod by
llo quaIily of llo surfaco proparalion usod. Tlo spocific
mollod of surfaco proparalion is an inlograI parl of llo
Ropair Syslom and ils quaIificalion. Any clango in llo
surfaco proparalion mollod roquiros roquaIificalion of
llo Ropair Syslom (soo Mandalory Appondix VIII).
3.2.3 5hert-1erm 1est ata. Tloso slaII incIudo lon-
siIo slrongll, uIlimalo lonsiIo slrain, and moduIus in
boll llo loop and axiaI diroclions, and llo slrongll of
llo adlosivo bond bolvoon llo ropair Iaminalo and llo
subslralo maloriaI and oplionaIIy llo onorgy roIoaso ralo
of llo Ropair Syslom.
3.2.4 Leng-1erm 1est ata. Tloso slaII incIudo llo
slrongll of llo adlosivo bond bolvoon llo ropair Iami-
nalo, subslralo, and fiIIor maloriaI and oplionaIIy llo
uIlimalo lonsiIo slrain of llo ropair Iaminalo.
Iong-lorm is dofinod as groalor or oquaI lo 1,000 lr.

1abIe 1 kepair 5ystem kequired MateriaI and PerIermance Preperties

Mechanlcal prcpertles Ycung's mcdulus lSU 527 ASTM u 3039
Pclsscn's ratlc lSU 527 ASTM u 3039
Shear mcdulus (ln-plane) . . . ASTM u 5379
Thermal expanslcn ccefflclents lSU 11359-2 ASTM F 831
6lass transltlcn temperature cf lSU 11357-2 ASTM u 660/, ASTM F 16/0,
pclymer (
) cr ASTM F 831
Feat dlstcrtlcn temperature (FuT) lSU 75 ASTM u 6/8
8arccl hardness 8S Fh 5 ASTM u 2583
Shcre hardness lSU 868 ASTM 22/0
8endlng mcdulus lSU 178 ASTM u 790
Adheslcn strength Lap shear 8S Fh 1/65 ASTM u 3165
Perfcrmance data Lcng-term strength (cptlcnal) Mandatcry Appendlx v . . .
Fnergy release rate (cptlcnal) Mandatcry Appendlx lv . . .
Structural strengthenlng (cptlcnal) Mandatcry Appendlx lll . . .
3.3 kequired ata
Tlo foIIoving dala slaII bo suppIiod for oacl ropair.
Tlo dolaiI lo vlicl lloso roquiromonls aro fuIfiIIod viII
bo dolorminod by llo oulpul of llo risI assossmonl.
OriginaI oquipmonl dosign dala, and mainlonanco and
oporalionaI lislorios slaII bo providod by llo ovnor and
maloriaI dala slaII bo providod by llo Ropair Syslom
suppIior. Tlo avaiIabiIily of roIovanl dala slouId bo con-
sidorod in llo risI assossmonl.
An oxampIo of a dosign dala slool is providod in
3.3.1 0riginaI quipment esign ata. Tlo foIIov-
ing iloms may bo roIovanl originaI oquipmonl dosign
dala:
piping Iino Iisls or ollor documonlalion sloving
procoss dosign condilions and a doscriplion of llo pip-
ing cIass incIuding maloriaI spocificalion, pipo vaII
llicInoss, and prossurolomporaluro raling
piping isomolric dravings incIuding sufficionl
dolaiIs lo pormil a piping fIoxibiIily caIcuIalion if llis
anaIysis is doomod nocossary
spocificalion of aII oporaling moclanicaI Ioads nol
incIudod in llo abovo, incIuding upsol condilions
originaI dosign caIcuIalions
3.3.2 Maintenance and 0peratienaI histery. Tlo foI-
Ioving iloms may bo roIovanl mainlonanco and opora-
lionaI lislory:
documonlalion of any significanl clangos in sor-
vico condilions incIuding prossuro, lomporaluro, fIuid
conlonl, and corrosion ralo
pasl sorvico condilions
134
summary of aII aIloralions and pasl ropairs IocaI
lo llo pipo soclion of concorn
inspoclion roporls dolaiIing llo naluro and oxlonl
of damago lo bo ropairod
3.3.3 5ervice Cenditien ata. Tlo foIIoving dala
slaII bo dolorminod:
Iifolimo roquiromonls/oxpoclalion of llo ropair
sorvico Iifo
roquirod dosign and oporaling prossuros (inlornaI
and oxlornaI)/lomporaluros
oxpoclod fuluro sorvico condilions
if appIicabIo, MAWI as slalod by llo ovnor or as
caIcuIalod according lo llo roquiromonls of ASMI B31G,
AII 579, or BS 7910
llo infIuonco of molaIIurgicaI dofocls, if appIicabIo
on llo MAWI slaII aIso bo considorod
3.4 esign MethedeIegy
3.4.1 0verview. Tlo dosign of llo ropair Iaminalo
slaII bo carriod oul using llo roquiromonls in llo foIIov-
ing soclions. Tloro aro lvo dosign casos:
Iipos nol IoaIing, roquiring
slrucluraI roinforcomonl onIy. Ono of llo foIIoving llroo
dosign mollods slaII bo usod:
IncIudo aIIovanco for originaI pipo (soo para.
3.4.3) vloro yioIding of llo pipo may or may nol bo
incIudod.
IxcIudo aIIovanco for originaI pipo (soo
para. 3.4.4).
Iong-lorm porformanco losl dala (soo
para. 3.4.5).
(08)
(08)
(08)

1abIe 2 5ervice 1emperature Limits Ier kepair
5ystems

can be measured
30C (5/F)
20C (36F)
cannct be measured FuT 20C (36F) FuT 15C (27F)

Iipos roquiring slrucluraI roin-
forcomonl and soaIing of llrougl-vaII dofocls (IoaIs).
Tlo dosign mollod in para. 3.4.6 slaII bo usod
in addilion lo llo Typo A dosign caso.
Ior pipos vill aclivo inlornaI corrosion, llo
ropair Iaminalo slaII bo dosignod on llo assumplion
llal a llrougl-vaII dofocl viII occur if llo romaining
vaII llicInoss al llo ond of sorvico Iifo is oxpoclod lo
bo Ioss llan 1 mm (0.04 in.).
Tlo groalor llicInoss of llo Typo A and Typo B dosign
caso slaII bo laIon as llo ropair Iaminalo llicInoss,
ropair
.
Tlo Typo B caso is oflon llo Iimiling dosign caso.
Iaragrapls 3.4.9 and 3.4.10 slaII bo considorod for
oacl dosign caso and appIiod vloro approprialo, vill
llo Iargosl llicInoss boing laIon as llo ropair Iaminalo
llicInoss,
ropair
.
3.4.2 5ervice 1emperature IIects. Ior dosign lom-
poraluros,
, groalor llan 40C (104I), llo Ropair

Syslom slaII nol bo usod abovo llo gIass lransilion lom-
poraluro,
, Ioss 30C (54I). Ior Ropair Sysloms vloro
cannol bo moasurod, llo Ropair Syslom slaII nol bo

usod abovo llo loal dislorlion lomporaluro (HDT) Ioss
20C (36I).
Ior Ropair Sysloms vloro llo subslralo is nol IoaIing
(Typo A dosign caso), llo lomporaluro Iimil can bo
roIaxod lo
Ioss 20C (36I) or HDT Ioss 15C (27I).
or HDT slaII bo moasurod in accordanco vill TabIo 1.

TabIo 2 summarizos lloso uppor lomporaluro Iimils
for llo Ropair Syslom.
Ior sorvico lomporaluros Ioss llan or oquaI lo 40C
(104I) adoqualo curo of llo fioId-appIiod ropair Iami-
nalo or adlosivo may bo domonslralod by BarcoI lard-
noss or Sloro lardnoss in accordanco vill TabIo 1. Ior
lloso condilions no accoplanco criloria IinIod lo
or
HDT aro slipuIalod. Moasurod lardnoss vaIuos slaII bo
nol Ioss llan 90 of llo minimum oblainod from Ropair
Syslom quaIificalion.
In absonco of ollor Ropair Syslom quaIificalion dala
|soo para. II-3(b) of Mandalory Appondix II], for sorvico
lomporaluros groalor llan 40C (104I) llo aIIovabIo
slrains lo bo usod in oqs. (7) and (8), and llo sorvico
faclors lo bo usod in oqs. (9), (12), (13), and (14) slaII bo
dovn-ralod by llo lomporaluro faclor,
, givon in oqs. (1)

and (2).
135

6 10
-5
(
)
2
+ 0.001 (
) + 0.7014 (1)

2 10
-5
(
)
2
+ 0.006 (
) + 0.7014 (2)
3.4.3 Pipe AIIewabIe 5tress. Uso of llo dosign
mollod in llis soclion is approprialo if llo conlribulion
of llo pipo is lo bo incIudod in llo caIcuIalion for Ioad-
carrying capabiIily.
Ior piping sysloms, oqs. (3) and (4) slaII bo usod. In
llo dorivalion of lloso oqualions il is assumod llal llo
undorIying subslralo doos nol yioId.
Ior loop slrossos duo lo inlornaI prossuro, llo mini-
mum ropair Iaminalo llicInoss,
min
, is givon by
min
) (3)
Ior axiaI slrossos duo lo inlornaI prossuro, bonding,
and axiaI llrusl, llo minimumropair Iaminalo llicInoss,
min
, is givon by
min
(4)
Tlo dosign ropair Iaminalo llicInoss,
ropair
, slaII bo
llo groalor vaIuo dolorminod from oqs. (3) and (4).
Wloro llo purposo of llo Ropair Syslom is lo
slrongllon an undamagod soclion of pipo lo carry addi-
lionaI bonding or ollor axiaI Ioads, llo vaIuo of slaII
bo laIon lo bo llo incroasod lolaI axiaI Ioad roquiromonl
and llo vaIuo of
slaII bo llo originaI MAWI. Tlo

vaIuo of doponds on llo spocific appIicalion dolaiIs
and slaII bo considorod by llo Ropair Syslom dosignor
(oulsido llo scopo of llis ArlicIo).
Ior pipoIinos, oq. (5) or (6) slaII bo usod. In llo doriva-
lion of oqs. (5) and (6) il is assumod llal llo undorIying
subslralo doos yioId and llo ropair Iaminalo is dosignod
basod on llo aIIovabIo slrain of llo composilo. OnIy
loop Ioading is considorod in dolormining llo dosign
ropair Iaminalo llicInoss.
Ior loop slrain duo lo inlornaI prossuro, llo dosign
ropair Iaminalo llicInoss,
ropair
, may bo caIcuIalod by
iloralion using

ropair

ropair
Iivo
2(
ropair
+
)
(5)
If llo ropair is appIiod al zoro inlornaI prossuro, i.o.,
Iivo
0, llon oq. (5) can bo roarrangod lo givo
ropair
(6)
Tlo assumplions mado in doriving oqs. (5) and (6)
aro llal llo subslralo maloriaI is oIaslic, porfoclIy pIaslic,
i.o., no slrain lardoning and llal no dofocl assossmonl
(08)
(08)

1abIe 3 AIIewabIe (Leng 1erm) 5trains Ier kepair
Laminates (he AIIewance Ier 1emperature IIects)

Fcr
0.5
0
0./0 0.25
Fcr
0.5
Clrcumferentlal
0
0./0 0.25
Axlal
0
0.25 0.10
is porformod ollor llan uso of llo minimum romaining
vaII llicInoss (of llo subslralo) lo infor llo inlornaI
prossuro al llo poinl of subslralo yioId.
Tlo vaIuo of llo aIIovabIo slrain of llo composilo in
llo circumforonliaI diroclion can bo laIon from oq. (9)
or if porformanco dala aro avaiIabIo, from Mandalory
Appondix V. Tlo approprialo sorvico faclor is laIon from
TabIo 4.
3.4.4 kepair Laminate AIIewabIe 5trains. Uso of llo
dosign mollod in llis soclion is approprialo if llo conlri-
bulion of llo originaI pipo is lo bo ignorod in llo caIcuIa-
lion for Ioad-carrying capabiIily and if slorl-lorm
maloriaI proporlios aro lo bo usod.
Tlo aIIovabIo ropair Iaminalo slrain dosign mollod
is a funclion of dosign lomporaluro.
min
, is givon by
min
2
1
(7)
min
, is givon by
min
(8)
ropair
, slaII bo
llo groalor vaIuo dolorminod from oqs. (7) and (8).
RaroIy occurring ovonls (o.g., prossuro oxcursions
abovo dosign prossuro) may bo assossod using llo slrains
givon in TabIo 3, providod llal lloy occur lypicaIIy Ioss
llan 10 limos in llo Iifo of llo compononl vill oacl
duralion Ioss llan 30 min.
Tlo conlinuous (suslainod) Iong-lorm aIIovabIo
slrains Iislod in TabIo 3 slaII onIy bo usod if llo slorl-
lorm lonsiIo slrain lo faiIuro of llo ropair Iaminalo is al
Ioasl 1, ollorviso porformanco dala dorivod according
lo para. 3.4.5 slaII bo usod. Tlo slorl-lorm slrain lo
faiIuro slaII bo dorivod fromllo losl carriod oul lo dolor-
mino llo lonsiIo proporlios of llo Iaminalo (TabIo 1).
Somo Ropair Syslom suppIiors may clooso lo uso Iam-
inalo anaIysis lo caIcuIalo moduIus vaIuos for Iaminalos
buiIl up from a sorios of difforonl Iayors. Tlis is salisfac-
lory, providod llal llo rosuIls from llo Iaminalo anaIysis
lavo boon vaIidalod using moasurod dala.
136
1abIe 4 5ervice Facters Ier kepair Laminates

1,000 hr data 0.5
ueslgn llfe data 0.67
TlormaI oxpansion coofficionls for composilo Ropair
Sysloms aro difforonl llan lloso for llo subslralo, so
llormaI slrossos viII bo gonoralod vloro oporaling lom-
poraluros vary frominslaIIalion lomporaluro. Wloro llis
absoIulo lomporaluro clango is groalor llan 40C (72I),
llo offocl of difforonliaI llormaI oxpansion bolvoon llo
ropair Iaminalo and llo subslralo slaII bo considorod in
llo dosign assossmonl.
Tlo aIIovabIo ropair Iaminalo slrains (circumforonliaI
and axiaI) slaII bo caIcuIalod by

0
(

) (9)

0
(

)
vloro
0
and
0
aro from TabIo 3.
3.4.5 kepair Laminate AIIewabIe 5tresses eter-
mined by PerIermance 1esting. Uso of llo dosign
mollod in llis soclion is approprialo if porformanco-
basod losl dala aro avaiIabIo.
Mandalory Appondix V providos llroo aIlornalivo
mollods for llo dolorminalionof Iong-lormfaiIuro slross
(or slrain).
If aIIovanco for pipo is nol lo bo incIudod, llon oq. (10)
slaII bo usod.
min
, is givon by
min
2

1

(10)
min
, is givon by oq. (4) or (8), as approprialo.
ropair
, slaII bo
llo groalor of llo vaIuos dolorminod.
If aIIovanco for llo pipo is lo bo incIudod, llon oq. (11)
slaII bo usod.
Ior loop slrossos duo lo inlornaI prossuro, llo dosign
ropair
, is givon by
ropair
(11)
Tlo sorvico faclor, , is llo Iossor of llal oblainod from
TabIo 4 and from llo approprialo conslruclion codo.
3.4.6 Leaking Pipes and vesseIs. A (subslralo) pipo
or vossoI slaII bo considorod lo bo IoaIing if llo vaII
llicInoss al any poinl of llo affoclod aroa is dolorminod
lo bo Ioss llan 1 mm (0.04 in.) al llo ond of ils Iifo.
(08)
(08)

Uso of llo dosign mollod in llis soclion is approprialo
if llo pipo or vossoI is IoaIing or considorod lo bo IoaIing
al llo ond of ils Iifo. Tlo roquiromonls of llis soclion
aro in addilion lo lloso doscribod in para. 3.4.4 or 3.4.5.
Ior a circuIar or noar-circuIar dofocl, llo minimum
min
, is iloralod using oq. (12).

2
)
3
512
3
min
4
+
1
+
3
64
min
2
(12)
Tlo vaIuo of is sol lo 0.333 (or TabIo 4 if porformanco
dala is avaiIabIo).
Ior noncircuIar dofocls llal lavo an aspocl ralio Ioss
llan 5, oq. (12) slaII bo usod vloro llo vaIuo of is
soIoclod sucl llal il conlains llo dofocl.
Wloro llo Ropair Syslom incorporalos a pIug lo aIIov
llo ropair of a Iivo pipo or vossoI, llo quaIificalion losls
carriod oul lo dolormino llo vaIuo of (Mandalory
Appondix IV) slaII bo conduclod on llo vloIo Ropair
Syslom incIuding any pIug arrangomonl.
Ior a sIol or roclanguIar lypo dofocl, vloro llo vidll
of llo sIol, , salisfios 1.65
min
, llo minimum
min
, is iloralod using

2
)
1
24
3
min
4
+
4
+
3
16
min
4
5
+
2
(1 + )

2
(13)
As llo sizo of llo dofocl incroasos, llo rosponso of llo
ropair Iaminalo viII clango from llal for a pIalo or boam
undor lransvorso Ioading lo llal for a cyIindricaI sloII
undor mombrano Ioading. Tlis circumslanco is ropro-
sonlod by (
min
) and llo rosponso of llo ropair
Iaminalo bocomos indopondonl of dofocl sizo. Ior a sIol
or roclanguIar lypo dofocl, vloro llo vidll of llo sIol,
, salisfios 1.65
min
, llo minimum ropair Iami-
nalo llicInoss,
min
, is iloralod using

8
min
(14)
Tlo vaIuo of and
2
in oqs. (12) lo (14) slaII bo laIon
as (
)
0.5
and (
), rospoclivoIy, as llo ropair

Iaminalo is anisolropic, i.o., llo proporlios of llo maloriaI
aro difforonl in llo axiaI and circumforonliaI diroclions.
3.4.7 Impact. Ior ropairs lo IoaIing pipos, llo sup-
pIior slaII domonslralo llal llo Ropair Syslomis capabIo
of villslanding a Iov voIocily 5 } (44.3 in.-Ib) impacl in
accordanco vill llo procoduro doscribod in Mandalory
Appondix VI.
137
Tlo ropair Iaminalo llicInoss, as dosignod por llis
ArlicIo, may bo insufficionl lo addross oxlornaI impacl
Ioads. Considoralion slouId bo givon lo incroasing llo
Iaminalo ropair llicInoss or providing ollor mollods
of proloclion.
3.4.8 AxiaI Length eI kepair. UnIoss il can bo dom-
onslralod llal a slorlor ropair Iongll is sufficionl, llo
dosign llicInoss of llo ropair Iaminalo slaII oxlond
boyond llo damagod rogion in llo pipo,
ovor
, by
ovor
2.5 /2 (15)
Ior ropairs dosignod in accordanco vill para. 3.4.6,
ovor
slaII bo llo groalor of
ovor
max. 2.5 /2 or

ropair
(16)
Tlo lolaI axiaI Iongll of llo ropair is givon by
2
ovor
+
dofocl
+ 2
lapor
(17)
Tlo onds of llo ropair slaII bo laporod if llo ropair
llicInoss is govornod by axiaI Ioads (paras. 3.4.4, 3.4.5,
and 3.4.6). A minimum lapor of approximaloIy 5:1 (lori-
zonlaI/vorlicaI) is rocommondod. Tlo ovorIap Iongll
slaII aIso bo dosignod lo bo sufficionl lo lransfor llo
axiaI Ioad.
3.4.9 Pipe Fittings. Iqualions (3) llrougl (11) roIalo
lo llo slrossos in llo subslralo (pipo) undor combinalions
of inlornaI prossuro and axiaI Ioad. Ior pipo fillings,
sucl as bonds, roducors, loos, and fIangos, llo slross
sysloms aro moro compIox and may nood furllor consid-
oralion. CaIcuIalions may bo basod on prossuro slross
muIlipIiors for pipo compononls laIon from ISO 14692.
Tlo prossuro slross muIlipIior for bonds, roducors, and
ollor compononls vloro llo mombrano slross duo lo
prossuro is llo samo as for simpIo pipo slaII bo laIon
as unily, and for loos slaII bo laIon as 2. Tlo diamolor
roquirod for ropair dosign is llo Iargosl diamolor of llo
compononl.
3.4.10 0ther esign Censideratiens. Iaragrapls
3. 4.10. 1 llrougl 3.4.10.6 nood onIy bo appIiod if
approprialo.
3.4.10.1 xternaI Leads. To rosisl oxlornaI pros-
suro or vacuum appIiod lo llo Ropair Syslom, llo mini-
mum ropair llicInoss,
min
, is givon by
min

2
)
1/3
(18)
Ior soiI Ioads, lo provonl llo coIIapso of a buriod
ropairod pipoIino, llo oxlornaI soiI prossuro
oxl, soiI
slaII
bo Ioss llan llo coI Iapso rosislanco of llo Ropair
Syslom,


oxl, soiI

2
2
)
min
3
(19)
vloro
oxl, soiI
2
8
+
1
3
+
2
2
soiI
vloro
2
is dofinod as (
).
3.4.10.2 CycIic Leading. CycIicaI Ioading slaII bo
considorod in llo risI assossmonl for llo appIicalion of
llo Ropair Syslom.
CycIic Ioading is nol nocossariIy Iimilod lo inlornaI
prossuro Ioads. TlormaI and ollor cycIic Ioads slouId
aIso bo considorod vlon assossing cycIic sovorily.
If llo prodiclod numbor of prossuro or ollor Ioading
cycIos is Ioss llan 7,000 ovor llo dosign Iifo, llon cycIic
Ioading doos nol roquiro considoralion as por ISO 14692.
cycIos oxcoods 7,000 ovor llo dosign Iifo, llon cycIic
Ioading slaII bo considorod using oqs. (20) and (21). Tlo
oqualions aro consorvalivo for Iovor numbors of cycIos.
cycIos oxcoods 10
8
ovor llo dosign Iifo llan in llo foIIov-
ing oqs. (20) and (21), llon slaII bo sol lo 10
8
.
Ior llo dosign of nonIoaIing dofocls, paras. 3.4.4 and
3.4.5, llo composilo aIIovabIo slrain in boll circumfor-
onliaI and axiaI diroclions,

and

oq. (9), slaII bo
doralod by llo faclor,
, vloro
is givon by
+
1
2.888Iog (

2
) (20)
Ior llo dosign of IoaIing pipos (para. 3.4.7), llo sorvico
faclor, , in oqs. (12) llrougl (14) slaII bo ropIacod by
0.333
2
+
1
2.888Iog (

2
) (21)
Tloso oqualions aro inlondod for cycIic inlornaI pros-
suro Ioading onIy, bul may bo appIiod vill caulion lo
axiaI Ioads, providod lloy romain lonsiIo, i.o., llo oqua-
lions aro nol appIicabIo for rovorsibIo Ioading.
3.4.10.3 Fire PerIermance. Tlo roquiromonls for
firo porformanco slaII bo idonlifiod in llo risI assoss-
monl. IIamo sproad and smoIo gonoralion slaII aIso bo
considorod in llo assossmonl. Duo accounl slaII bo laIon
of llo rosponso of llo Ropair Syslom |pipo (subslralo)
and llo ropair Iaminalo]. In many casos addilionaI firo
proloclion viII nol bo nocossary, as llo damagod originaI
pipo may sliII bo abIo lo porform salisfacloriIy during
llo slorl duralion of a firo ovonl.
Slralogios for aclioving firo porformanco incIudo llo
foIIoving:
138
appIicalion of addilionaI vraps of ropair Iaminalo
maloriaI sucl llal onougl basic composilo viII romain
inlacl for llo duralion of llo firo ovonl
appIicalion of inlumosconl oxlornaI coalings
appIicalion of inlumosconl and ollor onorgy
absorbonl maloriaIs villin llo ropair Iaminalo
uso of poIymor formuIalions vill spocific firo-
rolardanl proporlios.
Iurllor dolaiIs of firo porformanco and firo miligalion
mollods aro conlainod in ISO 14692.
3.4.10.4 IectricaI Cenductivity. Ior ropairs lo
molaIIic subslralos, il is IiIoIy llal llo proporlios of llo
subslral o viII salisfy oIoclricaI conduclivily
roquiromonls.
Wloro llo subslralo is insuIaling, o.g., GRI, and oIoc-
lricaI conduclivily roquiromonls aro spocifiod, llo oIoc-
lricaI conduclivily proporlios of llo Ropair Syslom
slouIdbo moasurodlo onsuro llal llo originaI claraclor-
islics of llo subslralo aro roslorod.
IIoclricaI conduclivily losling dolaiIs aro conlainod in
ISO 14692.
3.4.10.5 nvirenmentaI CempatibiIity. Tlo suil-
abiIily for uso of llo Ropair Syslom in llo sorvico onvi-
ronmonl slaII bo basod on llo foIIoving considoralions.
Tlo sorvico onvironmonl is llo onvironmonl llal viII
conlacl llo ropair Iaminalo. Il may bo oillor llo oxlornaI
or inlornaI onvironmonl. Wlon roquirod by llo sorvico
onvironmonl, llo Ropair Syslom slaII bo proloclod from
UV oxposuro (o.g., sunIigll), valor, and damaging
clomicaIs, oillor as an inloronl claraclorislic of llo
Ropair Syslom or by llo appIicalion of coaling or
moclanicaI barrior.
Tlo quaIificalion of llo Ropair Syslom (para. 3.2) slaII
onsuro llal llo Ropair Syslom is compalibIo vill aquo-
ous and lydrocarbon onvironmonls al llo quaIificalion
lomporaluro. In gonoraI, llormosol poIymors aro com-
palibIo vill a vido rango of onvironmonls bul considor-
alion noods lo bo givon vlonllo onvironmonl is slrongIy
acidic (pH 3.5), slrongIy aIIaIino (pH 11), or is a
slrong soIvonl, o.g., mollanoI, loIuono in conconlralion
groalor llan 25.
Wlon llo compalibiIily of llo Ropair Syslom is
unInovn, llon llo ropair Iaminalo suppIior slaII pro-
vido ono of llo foIIoving lo domonslralo compalibiIily:
onvironmonlaI compalibiIily dala from llo poIy-
mor suppIior, domonslraling llal llo onvironmonl is no
moro aggrossivo llan aquoous or lydrocarbon onviron-
monls al llo dosign lomporaluro
if no compalibiIily dala from llo poIymor suppIior
is avaiIabIo, llon spocific onvironmonlaI losling is
roquirod. RosuIls from losls according lo ono of llo foI-
Ioving losl procoduros, ASTM D 543, ASTM C 581,
ASTM D 3681, ISO 10952 or oquivaIonl, comparing llo
oxposuro of llo spocific onvironmonl and aquoous onvi-
ronmonl lo llo ropair Iaminalo al llo dosign lomporaluro

slaII bo porformod. Tlo Ropair Syslom slaII bo consid-
orod compalibIo lo llo spocific onvironmonl if llo losl
rosuIls from llo spocific onvironmonl aro no vorso llan
for llo aquoous onvironmonl.
Wlon orosion is llo causo of llo dogradalion procoss
of llo subslralo maloriaI and llo ropair Iaminalo is in
conlacl vill llo oroding modium, llon llo ropair Iami-
nalo may suffor maloriaI Ioss. Tlo Ropair Syslom sup-
pIior slaII domonslralo llal dospilo llis polonliaI Ioss
of Iaminalo maloriaI, llo Ropair Syslom slouId survivo
for llo spocifiod ropair Iifolimo.
3.4.10.6 Cathedic isbendment. Ior ropairs lo
pipos llal aro callodicaIIy proloclod, il may bo roquirod
lo domonslralo llal llo ropair viII nol disbond duo lo
llo callodic proloclion syslom.
ASTM G8 slaII bo usod lo domonslralo llal llo ropair
viII nol bo suscoplibIo lo di sbondmonl undor an
imposod oIoclricaI curronl.
3.4.11 esign 0utput. Tlo oulpuls of llo dosign
caIcuIalions of llo ropair Iaminalo aro llo foIIoving:
ropair llicInoss (numbor of vraps),
lolaI axiaI ropair Iongll,
Tlo dosign llicInoss of llo ropair slaII bo oxprossod
as numbor of vraps for inslaIIalion purposos

ropair
Iayor
(22)
vloro slaII bo nol Ioss llan 2.
3.5 ApprevaI
Dosigns of ropairs according lo llis ArlicIo slaII bo
aullorizod by a IrofossionaI Inginoor (or inlornalionaI
oquivaIonl) or slaII bo undorlaIon by a loclnicaIIy com-
polonl porson accoplabIo lo llo ovnor.
3.6 kequaIiIicatien
Wloro lloro las boon a clango lo llo Ropair Syslom,
llon llo losling spocifiod in llo roIovanl paras. 3.6.1 and
3.6.2 slaII bo compIolod.
If llo modifiod Ropair Syslom is found lo bo of Iovor
porformanco llan llo originaI syslom, llon il slaII bo
lroalod as a nov syslom and vaIidalod according lo llo
roquiromonls of llis ArlicIo.
If llo modifiod Ropair Syslom is found lo bo of liglor
porformanco llan llo originaI syslom, llon il may bo
lroalod as a nov syslom and vaIidalod according lo llo
roquiromonls of llis ArlicIo or llo dala from llo originaI
Ropair Syslom may bo usod.
3.6.1 Fer 1ype A kepairs
Tosl ing spocifiod in soclions II-2 and II-4 of
Mandalory Appondix II.
Wloro llo Ropair Syslom las boon vaIidalod
according lo soclion II-6 of Mandalory Appondix II, llo
syslom slaII bo subjocl lo llo survivaI losling spocifiod
in para. V-2.1 of Mandalory Appondix V.
139
3.6.2 Fer 1ype kepairs
Tosl ing spocifiod in soclions II-2 and II-3 of
Mandalory Appondix II.
Tosling spocifiod in soclion II-5 of Mandalory
Appondix II.
NOTI: OnIy llroo losls aro roquirod and rosuIls slaII bo com-
parod vill

of llo originaI Ropair Syslom.
4 FAkICA1I0h (Ih51ALLA1I0h)
4.1 CeneraI
Tlo ropair llicInoss lo bo inslaIIod slaII bo oxprossod
as llo numbor of vraps lo bo appIiod (basod on llo
minimumllicInoss por vrap dolorminod during vaIida-
lion), soo para. 3.4.11.
4.2 MateriaIs eI Censtructien
Tlo maloriaIs of conslruclion slaII bo lloso for vlicl
llo quaIificalion and dosign las boon compIolod.
4.3 5terage Cenditiens
Slorago of maloriaI slaII compIy vill llo suppIiors
inslruclions. Tlo MSDS slaII bo rolainod for roforonco.
Il slouId bo nolod llal llo maloriaIs usod viII nood lo
bo slorod and conlroIIod according lo nalionaI safoly
roguIalions (o.g., OSHA or COSHH).
4.4 Methed 5tatements
InslaIIalion of a Ropair Syslom slaII bo covorod by a
mollod slalomonl, vlicl doscribos oacl of llo main
procoduros lo bo carriod oul.
Inpul lo llo mollod slalomonl comos from llo
foIIoving:
risI assossmonl (suppIiod by ovnor)
vorIing condilions (suppIiod by ovnor)
dosign informalion
pIanl oporaling condilions, Iayoul, olc. (sup-
pIiod by ovnor)
dosign of ropair (suppIiod by Ropair Syslom
suppIior)
maloriaIs informalionfor Ropair Syslom(suppIiod
by Ropair Syslom suppIior)
TypicaIIy llo mollod slalomonl incIudos informalion
spocifiod in paras. 4.4.1 llrougl 4.4.5.
4.4.1 heaIth and 5aIety
Iisl of maloriaIs lo bo landIod, incIuding copios
of MSDS.
NalionaI safoly roguIalions (o.g., OSHA, COSHH)
assossmonl for procoss.
DolaiIs of porsonaI proloclivo moasuros lo bo
adoplod.
Iisl of lazards associalod vill oquipmonl lo bo
ropairod and oquipmonl in llo vicinily of llo ropair silo
vill proloclivo moasuros.

4.4.2 kepair esign
DolaiIs of Iaminalo Iay-up, incIuding numbor of
vraps, ropair aroa covorod, and orionlalion of individuaI
Iayors of roinforcomonl (llis may bo prosonlod as a vril-
lon doscriplion or a draving incorporaling slandard
dolaiIs sucl as ovorIap and lapor and lapor Iongll
informalion).
DolaiIs of surfaco proparalion procoduro, incIud-
ing mollod of appIicalion, oquipmonl lo bo usod, and
inspoclion mollod.
DolaiIs of in-fiII roquirod lo acliovo a smooll oulor
profiIo prior lo llo appIicalion of llo ropair Iaminalo.
4.4.3 kepair AppIicatien
DolaiIs of limo Iimilalions bolvoon slagos of llo
ropair, o.g., bolvoon surfaco proparalion and Iaminalion.
DolaiIs of Iay-up procoduro incIuding if llo ropair
Iaminalo is lo bo appIiod in slagos.
DolaiIs of curing procoduro incIuding poslcuring
if nocossary.
4.4.4 uaIity Assurance
DolaiIs of loId/inspoclion poinls during llo
Ropair Syslom appIicalion (para. 4.6 and Mandalory
Appondix VIII).
DolaiIs of any maloriaIs losls lo bo carriod oul (if
spocifiod by ovnor or llo Ropair Syslom suppIior).
DolaiIs of any prossuro syslom losls lo bo carriod
oul (soo soclion 6).
4.4.5 nvirenmentaI. Informalion on disposaI of
unusod maloriaIs and vaslo.
4.5 InstaIIer uaIiIicatiens
IorsonnoI invoIvod in llo inslaIIalion of a Ropair Sys-
lom slaII bo lrainod and quaIifiod according lo
Mandalory Appondix VII.
4.6 InstaIIatien Cuidance
Ropair Syslom suppIiors slaII provido fuII inslaIIalion
inslruclions. Tloso inslruclions slaII incIudo (vloro
approprialo)
accoplabIo onvironmonlaI condilions of silo al limo
of ropair
maloriaI slorago
surfaco proparalion
poIymor mixing
Iaminalo Iay-up
Iaminalo consoIidalion
curo
Ioy loId poinls
Iurllor dolaiIs of lloso roquiromonls can bo found in
Mandalory Appondix VIII.
Tlo Ioy loId poinls llal may bo obsorvod during a
ropair aro summarizod in TabIo 5.
Tlo rosuIls of llo losls on llo ropair Iaminalo slaII
bo comparod vill llo quaIificalion dala. Accoplanco
140
1abIe 5 heId Peints uring InstaIIatien

Methcd statement lnstaller
Materlals preparatlcn lnstaller
relnfcrcement
pclymer
Surface preparatlcn lnstaller cr supervlscr
lnspectlcn
Flller prcflle lnstaller
Stage check cn relnfcrcement lay-up lnstaller
Tests cn repalr lamlnate lnstaller cr supervlscr
cure (hardness)
thlckness
dlmenslcns
external lnspectlcn (see Table 6)
Pressure test lnspectlcn authcrlty
vaIuos of llo losl rosuIls slaII bo providod by llo poIy-
mor syslom suppIior prior lo Ropair Syslom inslaIIalion.
4.7 Live kepairs
Ropairs lo nonIoaIing, Iivo piping sysloms aro possi-
bIo, providod llal llo associalod lazards aro fuIIy con-
sidorod in llo risI assossmonl for llo oporalion. Tlis
slouId incIudo any lazards lo and from surrounding
oquipmonl in addilion lo llo pipo boing ropairod.
Tlo lonsiIo (radiaI) slrossos inducod inlo llo adlosivo
bond as a rosuIl of llo llormaI conlraclion difforoncos
bolvoon llo composilo and llo pipo upon llo romovaI
of Iivo Ioads aro nogIigibIo.
5 XAMIhA1I0h
5.1 Intreductien
Tlis soclion providos guidanco on llo posl-
inslaIIalion/oporalionaI issuos of Ropair Sysloms. Tlo
inslaIIalion of a Ropair Syslom viII nol affocl any inlor-
naI inspoclions llal may bo carriod oul.
Tlo main issuos for nondoslruclivo oxaminalion of
llo Ropair Syslom aro
llo inspoclion of llo ropair (composilo) Iaminalo
llo inspoclion of llo bond quaIily bolvoon llo
ropair Iaminalo and llo subslralo
llo inspoclion of llo subslralo
Tlo basic slrucluro of a composilo ropair in llis con-
loxl is considorod in Iig. 1.
5.2 eIects within the kepair 5ystem
Tlo Ropair Syslom suppIior slaII provido
posl-inslaIIalion visuaI inspoclion criloria. Guidanco on
(08)
(08)

Fig. 1 5chematic eI a kepair 5ystem and Lecatien eI eIects

dofocls and aIIovabIo Iimils llal aro IiIoIy lo bo of
imporlanco aro givon in TabIo 6. Tlo inslaIIor slaII laIo
caro lo onsuro llal lloso dofocls aro nol formod during
appIicalion of llo Ropair Syslom.
5.3 kepair eI eIects within the kepair 5ystem
Dry aroas in llo poIymor-ricl surfaco Iayor may bo
ropairod by abrading and cIoaning llo affoclod aroa and
llon volling oul vill moro poIymor.
Ropairs conlaining dofocls llal oxcood llo Iimils in
TabIo 6 slaII bo romovod in lloir onliroly and a nov
ropair inslaIIod. Hovovor, on agroomonl vill llo ovnor,
IocaI romovaI of llo damagod aroa and roappIicalion of
llo Ropair Syslom maloriaIs lo llis aroa aro aIIovabIo
if llo Ropair Syslom suppIior can domonslralo llal llis
viII rosloro llo fuII porformanco of llo ropair.
5.4 Inspectien Metheds
Rofor lo Ropair SyslomsuppIior for guidanco on moll-
ods for inspocling llo Ropair Syslom.
5.5 kepair 5ystem kepIacement 5trategy
Tlo mainlonanco and ropIacomonl slralogy for Ropair
Sysloms viII bo a funclion of llo lypo of originaI dofocl
in llo pipo.
Ior abovo-ground piping sysloms, visuaI inspoclion
of llo ropair Iaminalo for dofocls in accordanco vill
TabIo 6 is rocommondod as parl of llo mainlonanco
slralogy. Tlo froquoncy of inspoclion slouId bo dolor-
minod in accordanco vill llo risI assossmonl. If dofocls
aro Iocalod, llon furllor assossmonl viII bo roquirod.
If llo assossmonl dolorminos llal ropIacomonl is
roquirod, llon ropIacomonl oplions incIudo
romovaI of llo ropair (o.g., llrougl uIlra-ligl
prossuro valor jolling) and ropIacomonl
ropair llo ropair Iaminalo. In llis caso llo dam-
agod ropair Iaminalo slaII bo considorod as llo dofocl for
dosign purposos and a nov ropair dosignod according lo
para. 3.4
IocaIizod ropair of llo damagod aroa, para. 5.3
5.5.1 xternaI eIects. Ior oxlornaI dofocls, il is
assumod llal furllor dolorioralion of llo dofocl is
sloppod on appIicalion of llo ropair Iaminalo. Tloroforo,
141
llo mainlonanco slralogy viII bo lo onsuro llal llo ropair
Iaminalo romains inlacl, i.o., llo ropair Iaminalo is nol
damagod or doIaminalod in parl from llo subslralo.
5.5.2 InternaI er 1hreugh-waII eIects. Ior inlornaI
corrosion or llrougl-vaII dofocls, furllor dolorioralion
or grovll of llo dofocl may conlinuo dospilo appIicalion
of llo ropair Iaminalo. Tloroforo, in addilion lo llo
roquiromonls sol oul inpara. 5.5.1, llo mainlonanco slral-
ogy slouId onsuro llal llo inlornaI dofocl doos nol grov
lo a sizo groalor llan assumod in llo dosign of llo ropair
or llal llo ropair Iaminalo doos nol doIaminalo from
llo subslralo pipo.
Tlo froquoncy of inspoclion slouId bo dolorminod in
accordanco vill llo risI assossmonl.
If llo dosign assossmonl dolorminos llal llo Ropair
Syslom is no Iongor fil for purposo, llon mainlonanco/
ropair oplions slouId bo considorod, as doscribod in
ASMI ICC-2, bul a (composilo) Ropair Syslom may sliII
bo llo bosl soIulion.
6 551M Pk55bk 151IhC
Syslom prossuro losling, if roquirod, slaII bo spocifiod
by llo ovnor.
AII ropairs slaII bo curod in accordanco vill llo
Ropair Syslom suppIior inslruclions boforo prossuro
losling.
A sorvico losl of nol Ioss llan 1.0 limos llo oporaling
prossuro is rocommondod for a poriod of al Ioasl 60 min
ovor vlicl any clangos in prossuro and lomporaluro
slaII bo rocordod. Any signs of IoaIago or indicalion of
ropair Iaminalo faiIuro slaII bo causo for rojoclion of llo
ropair.
If llo losl prossuro oxcoods llo prossuro for vlicl
llo Ropair Syslom las boon dosignod, llon llis liglor
prossuro slaII bo considorod as a soparalo dosign caso.
Ior llo purposos of llo caIcuIalion, llo losl condilion
may bo lroalod as an occasionaI Ioad.
7 kFkhC5
7.1 keIerenced Cedes and 5tandards
Tlo foIIoving is a Iisl of pubIicalions roforoncod in
llis ArlicIo.
(08)

1abIe 6 eIect 1ype and AIIewabIe Limits Ier the Cempesite wrap

kepalr materlal and Check that substrate materlal are thcse
substrate plpe prlcr speclfled by deslgn
tc repalr appllcatlcn
Changes ln gecmetry kepalr area tc be free cf sharp changes ln
gecmetry |all radll 5 mm (0.2 ln.)[, cr
sharp gecmetry tc be falred-ln
Surface preparatlcn ln acccrdance wlth kepalr System speclfl-
catlcn
Axlal extent tc be ln acccrdance wlth deslgn
Surface temperature ln acccrdance wlth repalr deslgn
uefect ulmenslcns dc nct exceed thcse fcr whlch
the repalr has been deslgned
uefect nature tc be that fcr whlch the repalr
has been deslgned
Lccatlcn cf repalr Axlal extent and pcsltlcnlng tc be ln acccr-
dance wlth deslgn
lnterface uelamlnatlcn Tap test may lndlcate presence cf debcndlng
hcne at ends cf repalr
Pclymer-rlch layer Cracks hcne (check adheslve flllets)
Fcrelgn matter, bllsters, and plts Maxlmum 10 mm (0./ ln.) ln wldth, 2.5 mm
(0.1 ln.) ln helght
wrlnkles hc step changes ln thlckness greater than
2.5 mm (0.1 ln.) ln helght
Pln hcles hcne deeper than pclymer-rlch layer
Pclymer cclcr unlfcrm
ury spcts hcne
Ccmpcslte lamlnate Flber crlentatlcn As speclfled ln deslgn
unlmpregnated]dry flber hcne
Fxpcsed, cut edges]flbers hcne
Fcrelgn matter hcne
Axlal extent and pcsltlcnlng cf the repalr As speclfled ln the deslgn
uces nct extend beycnd prepared surface
AII 579/ASMI IIS-1, Iilnoss-Ior-Sorvico (Ialosl
odilion)
ASMI B31.4-2006, IipoIino Transporlalion Sysloms for
Iiquid Hydrocarbons and Ollor Iiquids
ASMI B31.8-2007, Gas Transmission and Dislribulion
Iiping Sysloms
ASMI B31G-1991, ManuaI: Dolormining Romaining
Slrongll of Corrodod IipoIinos: SuppIomonl lo B31
Codo Irossuro Iiping
ASMI ICC-22008, Ropair of Irossuro Iquipmonl and
Iiping
142
ASTM C 581-2003, Slandard Iraclico for Dolormining
ClomicaI Rosislanco of Tlormosolling Rosins Usod
in GIass-Roinforcod Slrucluros Inlondod for Iiquid
Sorvico
ASTM D 543-1995, Slandard Iraclicos for IvaIualing llo
Rosislanco of IIaslics lo ClomicaI Roagonls
ASTM D 648-2004, Slandard Tosl Mollod for DofIoclion
Tomporaluro of IIaslics Undor IIoxuraI Ioad in llo
Idgoviso Iosilion
ASTM D 790-2003, Slandard Tosl Mollod for IIoxuraI
Iroporlios of Unroinforcod and Roinforcod IIaslics
and InsuIaling MaloriaIs

ASTM D 1598-2002, Tosl Mollod for llo Timo lo IaiIuro
of IIaslic Iipo Undor Conslanl InlornaI Irossuro
ASTM D 1599-1999, Tosl Mollod for Slorl Timo
HydrauIic IaiIuro Irossuro of IIaslic Iipo, Tubing and
Iillings
ASTM D 2240-2005, Slandard Tosl Mollod for Rubbor
Iroporly Duromolor Hardnoss
ASTM D 2583-1995, Slandard Tosl Mollod for
Indonlalion Hardnoss of Rigid IIaslics by Moans of
a BarcoI Improssor
ASTM D 2992-2001, Iraclico for Oblaining Hydroslalic
or Irossuro Dosign Basis for GIass Iibor Roinforcod
Tlormosolling Rosin Iipo and Iillings
ASTM D 3039-2000, Slandard Tosl Mollod for TonsiIo
Iroporlios of IoIymor Malrix Composilo MaloriaIs
ASTM D 3165-2000, Slandard Tosl Mollod for Slrongll
Iroporlios of Adlosivos in Sloar by Tonsion Ioading
of SingIo-Iap-}oinl Iaminalod AssombIios
ASTM D 3681-2001, Slandard Tosl Mollod for ClomicaI
Rosislanco of IiborgIass (GIass-Iibor-Roinforcod
Tlormosolling Rosin) Iipo in a DofIoclod Condilion
ASTM D 5379-1998, Slandard Tosl Mollod for Sloar
Iroporlios of Composilo MaloriaIs by llo V-Nolclod
Boam Mollod
ASTM D 6604-2000, Slandard Iraclico for GIass
Transilion Tomporaluros of Hydrocarbon Rosins by
DifforonliaI Scanning CaIorimolry
ASTM I 831-2003, Slandard Tosl Mollod for Iinoar
TlormaI Ixpansion of SoIid MaloriaIs by
TlormomoclanicaI AnaIysis
ASTM I 1640-1999, Slandard Tosl Mollod for
Assignmonl of llo GIass Transilion Tomporaluro By
Dynamic MoclanicaI AnaIysis
ASTM G 8-1996, Slandard Tosl Mollods for Callodic
Disbonding of IipoIino Coalings
(ASTMInlornalionaI), 100 Barr Harbor Drivo, I.O. Box
BS IN 59-1977, Moasuromonl of Hardnoss by Moans of
a BarcoI Improssor
BS IN 1465-1995, Dolorminalion of TonsiIo Iap Sloar
Slrongll of Rigid lo Rigid Bondod AssombIios
BS 7910-1999, Guido on Mollods for Assossing llo
AccoplabiIily of IIavs in MolaIIic Slrucluros
IubIislor: Brilisl Slandards Inslilulion, Inc. (BSI), 12110
Sunsol HiIIs Road, Roslon, VA 20190-5902
ISO 75-1993, IIaslics Dolorminalion of Tomporaluro
of DofIoclion Undor Ioad
ISO 178-2001, IIaslics Dolorminalion of IIoxuraI
Iroporlios
ISO 527-1993, IIaslics Dolorminalion of TonsiIo
Iroporlios
ISO 868-2003, IIaslics and Ibonilo Dolorminalion of
Indonlalion Hardnoss by Moans of a Duromolor
(Sloro Hardnoss)
143
ISO 8501-1988, Iroparalion of SlooI Subslralos Boforo
AppIicalion of Iainls and RoIalod Iroducls
ISO 8502-1992, Tosls for llo Assossmonl of SlooI
CIoanIinoss
ISO 8503-1988, Surfaco Rouglnoss Claraclorislics of
BIasl CIoanod SlooI Subslralos
ISO 8504-2000, Surfaco Iroparalion Mollods
ISO 10952-1999, IIaslics Iiping Sysloms GIass-
Roinforcod Tlormosolling IIaslics (GRI) Iipos and
Iillings Dolorminalion of llo Rosislanco lo Clomi-
caI AllacI Irom llo Insido of a Soclion in a DofIoclod
Condilion
ISO 11357-2-1999, IIaslics DifforonliaI Scanning
CaIorimolry (DSC) Iarl 2: Dolorminalion of GIass
Transilion Tomporaluro
ISO 11359-2-1999, IIaslics TlormomoclanicaI anaIy-
sis (TMA) Iarl 2: Dolorminalion of Coofficionl of
Iinoar TlormaI Ixpansion and GIass Transilion Tom-
poraluro
ISO 13623-2000, IolroIoum and NaluraI Gas
Induslrios IipoIino Transporlalion Sysloms
Induslrios GIass Roinforcod IIaslic (GRI) Iiping
Induslrios Iiping
IubIislor: InlornalionaI Organizalion for
Slandardizalion (ISO), 1 cl. do Ia Voio-Crouso, Caso
poslaIo 56, CH-1211, Gono`vo 20, SvilzorIand/Suisso
7.2 keIated Cedes and 5tandards
Tlo foIIoving aro roIalod codos and slandards. UnIoss
ollorviso spocifiod, llo mosl roconl slandard (Ialosl odi-
lion) avaiIabIo slaII bo usod.
ASMI BoiIor and Irossuro VossoI Codo, Soclion III,
Division 1, Subsoclion ND (ND-3611.2), Ii ping
Dosign/GonoraI Roquiromonls/AccoplabiIily/Slross
Iimils
Division 1, Subsoclion ND |ND-3672.6(a)], Iiping
Dosign/GonoraI Roquiromonls/Ixpansion and
IIoxibiIily/Slrossos/Slross Rango
ASMI B31.5, Rofrigoralion Iiping
ASMI B31.9, BuiIding Sorvicos
ASMI B31.11, SIurry Transporlalion Iiping Sysloms
ASTM D 638, Slandard Tosl Mollod for TonsiIo
Iroporlios of IIaslics
ASTM D 696, Slandard Tosl Mollod for Coofficionl of
and 30C Will Vilroous SiIica DiIalomolor
ASTMD 903, Slandard Tosl Mollod for IooI or Slripping
Slrongll of Adlosivo Bonds

ASTM D 1763, Slandard Spocificalion for Ipoxy Rosins
ASTM D 2105, Slandard Tosl Mollod for IongiludinaI
TonsiIo Iroporl ios of IiborgIass (GIass-Iibor-
Roinforcod Tlormosolling-Rosin) Iipo and Tubo
ASTM D 2344, Slandard Tosl Mollod for Slorl-Boam
Slrongll of IoIymor Malrix Composilo MaloriaIs and
Tloir Iaminalos
ASTM D 2837, Slandard Tosl Mollod for Oblaining
Hydroslalic Dosign Basis for TlormopIaslic Iipo
MaloriaIs
ASTM D 3846, Slandard Tosl Mollod for In-IIano Sloar
Slrongll of Roinforcod IIaslics
ASTM I 412, Slandard TorminoIogy RoIaling lo IIaslic
Iiping Sysloms
AWWA C-150/A21.51, Slandard for TlicInoss Dosign
of DucliIo Iron Iipo
AWWA C-151/A21.51, Slandard for DucliIo Iron Iipo,
ConlrifugaIIy Casl, for Walor or Ollor Iiquids
AWWA C-200, Slandard for SlooI Walor Iipo 6 in. and
Iargor
AWWA M-11, SlooI Iipo A Guido for Dosign and
InslaIIalion
144
IubIislor: Amorican Walor WorIs Associalion (AWWA),
6666 Wosl Quincy Avonuo, Donvor, CO 80235
BS 2782: Iarl 10, Mollod 1001, Moasuromonl of
Hardnoss by Moans of a BarcoI Improssor
CSWII, CSWII-GRI-1-96 and CSWII-GRI-2-96, as por
ISO 8503
NTS-GRI-I}S/01 and NTS-GRI-INSI/01, NTS GRI
GuidoIinos for ApprovaI Sclomos for Iillors, }oinors,
Suporvisors and Inspoclors
ISO IN 13121, GRI lanIs and vossoIs for uso abovo
ground
ISO 14129, Iibro-Roinforcod IIaslic Composilos
Dolorminalion of llo In-IIano Sloar Slross/Sloar
Slrain Rosponso, IncIuding llo In-IIano Sloar
ModuIus and Slrongll, by llo IIus or Minus 45 dogroo
Tonsion Tosl Mollod
ISO 15310, Iibro-Roinforcod IIaslic Composilos
Dolorminalion of llo In-IIano Sloar ModuIus by llo
IIalo Tvisl Mollod

esign ata 5heet
Tlis Appondix providos an oxampIo of a dosign dala slool as roforoncod in para. 3.3. of ArlicIo 4.1.
145

146

147

uaIiIicatien ata
II-1 Ih1k0bC1I0h
Tlis Appondix doscribos llo quaIificalion dala llal
llo Ropair SyslomsuppIior slaII provido lo bo in compIi-
anco vill llis ArlicIo.
Il is a roquiromonl llal aII quaIificalion losls aro car-
riod oul using llo samo subslralo maloriaI, surfaco prop-
aralion, ropair Iaminalo, fiIIor maloriaI, adlosivo, and
appIicalion mollod (soo para. 1.1 of ArlicIo 4.1).
QuaIificalion losling slaII bo compIolod in accordanco
vill llo Ialosl vorsion of llo losl slandard. Updalos lo
llo losl slandards slaII nol roquiro quaIificalion losling
lo bo ropoalod.
II-2 A1A F0k kPAIk LAMIhA1
Tlo foIIoving dala aro roquirod:
pIy or Iayor llicInoss of llo (composilo) ropair
Iaminalo maloriaI.
lonsiIo moduIus, slrain lo faiIuro and slrongll in
llo circumforonl iaI diroclion dolorminod by losl
according lo TabIo 1 of ArlicIo 4.1.
lonsiIo moduIus, slrain lo faiIuro and slrongll in
llo axiaI diroclion dolorminod by losl according lo
TabIo 1.
Ioissons ralio in llo circumforonliaI diroclion (i.o.,
Ioad diroclion circumforonliaI, conlraclion axiaI) dolor-
minod by losl according lo TabIo 1 of ArlicIo 4.1.
sloar moduIus dolorminod by losl according lo
TabIo 1. Tlo losl spocimon goomolry slaII bo as slovn
in Iig. II-1.
aIlornalivoIy, llo sloar moduIus of llo poIymor
malrix may bo usod.
Fig. II-1 1est 5pecimen Ceemetry
148
BarcoI lardnoss or Sloro lardnoss dolorminod by
losl according lo TabIo 1 of ArlicIo 4.1.
gIass lransilion lomporaluro (
) or loal dislorlion
lomporaluro (HDT) for llo poIymor syslom subjoclod
lo llo samo llormaI lislory as ropairs appIiod on silo,
dolorminod by losl according lo TabIo 1 of ArlicIo 4.1.
llormaI oxpansion coofficionl in llo axiaI and cir-
cumforonliaI diroclions dolorminod by moasuromonl
(TabIo 1 of ArlicIo 4.1), caIcuIalion, or by roforonco lo
roIovanl loclnicaI Iiloraluro.
II-3 A1A F0k kPAIk]PIP Ih1kFAC
Tlo objoclivos of llo foIIoving losls aro nol lo produco
dala for uso in dosign. Tlo inlonl is lo domonslralo llal
an adlosivo bond can bo acliovod of adoqualo slrongll
anddurabiIily villllo ropair Iaminalo and surfaco prop-
aralion mollod. Il slouId bo nolod llal slorl-lorm
slrongll moasuromonls aro nol nocossariIy a good indi-
calor of Iong-lorm porformanco.
Tlo foIIoving Iap sloar losls slaII bo carriod oul:
Iap sloar slrongll dolorminod by losl according
lo TabIo 1. Tlis slorl-lormlosl slaII bo usod lo dolormino
llo avorago sloar slrongll or llo Iocus of faiIuro (ropair
Iaminalo romaining on a minimumof 30of llo bondod
aroa). Minimum avorago Iap sloar slrongll of 4 MN/m
2
(580 psi) slaII bo domonslralod for molaI subslralos.
AIlornalivoIy, il slaII bo domonslralod llal llo adlosivo
bond is slrongor llan llo Iap sloar slrongll of llo ropair
Iaminalo by assossing llo surfaco of llo subslralo malo-
riaI usod in a Iap sloar spocimon aflor losling.
Wloro ovidonco of Iong-lorm durabiIily of llo
adlosivo bond bolvoon llo ropair Iaminalo and llo sub-
slralo is roquirod and porformanco-basod losling las nol
boon carriod oul lo provido dala for dosign (soo para.
3.4.5 of ArlicIo 4.1), a Iong-lorm Iap sloar slrongll dolor-
minod by losl according lo TabIo 1 slaII bo porformod.
Tlis losl slaII bo carriod oul foIIoving immorsion in
valor (or ollor roIovanl modium) al llo dosign lompora-
luro |minimum 40C (104I)] for 1,000 lr. Tlo avorago
Iap sloar slrongll dolorminod from llis losl slaII bo al
Ioasl 30 of llo vaIuos from llo slorl-lorm Iap sloar
losls dolorminod abovo.
Ior sorvico abovo 100C (212I), llo foIIoving Iap
sloar losls slaII bo porformod:
aflor immorsion in valor al a minimum of 90C
(194I) for 1,000 lr and
(08)

aflor oxposuro in air al llo roquirod sorvico lom-
poraluro (
) for 1,000 lr
Tlo avorago Iap sloar slrongll dolorminod from lloso
losls slaII bo al Ioasl 30 of llo vaIuos from llo
slorl-lorm Iap sloar losls dolorminod abovo.
II-4 AI1I0hAL kbIkMh15 F0k
51kbC1bkAL kPAIk5 10 h0hLAkIhC PIP5
(1P A 5ICh CA5)
Tlo objoclivo of llo roforoncod losl is nol lo produco
dala for uso in dosign. Tlo inlonl is lo domonslralo
llal for a sovoro dofocl, adoqualo slrongll of llo Ropair
Syslom can bo acliovod. Tlo pipo spooI survivaI losl
(Mandalory Appondix III of ArlicIo 4.1) slaII bo com-
pIol od. Tlis losl nood onIy bo compIolod on ono
subslralo.
II-5 AI1I0hAL kbIkMh15 F0k LAkIhC
PIP5 (1P 5ICh CA5)
Tlo foIIoving dala slaII bo dolorminod:
bonding moduIus for llo (composilo) ropair Iami-
nalo dolorminod by losl according lo TabIo 1.
149
AIlornalivoIy, llo lonsiIo moduIus for llo Iaminalo may
bo usod as a consorvalivo oslimalo for llo vaIuo in
bonding.
fracluro louglnoss paramolor dolorminod by losl
according lo Mandalory Appondix V of ArlicIo 4.1.
impacl porformanco dolorminod by losl according
lo Mandalory Appondix VI of ArlicIo 4.1.
II-6 PkF0kMAhC 151IhC (0P1I0hAL
bALIFICA1I0h 1515)
Tlo Ropair Syslom suppIior may carry oul porform-
anco losling lo dolormino dosign aIIovabIos in accor-
danco vill Mandalory Appondix V of ArlicIo 4.1. Tlo
foIIoving dosign aIIovabIos aro dolorminod by oillor
of llo foIIoving:
Iong-lorm slrongll, oillor from 1,000 lr survivaI
losl or rogrossion losling.
Iong-lorm slrain lo faiIuro from roprosonlalivo
ropair Iaminalo rogrossion losling.
(08)

ArticIe 4.1, Mandatery Appendix III
5hert-1erm Pipe 5peeI 5urvivaI 1est
III-1 Ih1k0bC1I0h
Tlis Appondix doscribos llo losl mollod lo bo usod
lo domonslralo llal a Typo A dofocl can bo ropairod
using llo Ropair Syslom.
Tlo purposo of llis losl is lo confirm llo Ropair
Syslom las accoplabIo inlorIaminar sloar and bond
slrongll. Il domonslralos llo inlogrily of a slrucluraI
ropair up lo llo yioId IovoI of llo originaI pipo.
III-2 M1h0
Tlo foIIoving losl slaII bo compIolod using a slooI
pipo of al Ioasl 150 mm (6 in.) diamolor, and minimum
Iongll of six limos llo diamolor in addilion lo llo Iongll
of llo ropair. Tlo slooI pipo slaII lavo a minimum SMYS
of 235 10
6
N/m
2
(35,000 psi), o.g., ASTM A 106 Grado B
or inlornalionaI oquivaIonl.
Tlo Ropair Syslom suppIior can soIocl llo dopll of
llo dofocl, i.o., porconlago of vaII Ioss. Tlo Ropair
Syslom slaII bo quaIifiod onIy for dofocl doplls up lo
llis closon dopll.
A dofocl slaII bo maclinod in llo pipo lo a dopll
oquivaIonl lo llo vaII Ioss for vlicl llo Ropair Syslom
is boing quaIifiod. Tlo dofocl slaII lavo a Iongll, , of
a minimum of ono-laIf of llo pipo diamolor aIong llo
axiaI diroclion of llo pipo spooI, and a vidll, , of ono-
fourll of llo pipo diamolor around llo loop diroclion
of llo pipo spooI. A radius may bo maclinod oulsido
llo odgo of llo dofocl, bul llo dimonsions of maclinod
aroa slaII nol oxcood 2 nor 2, as slovn in Iig. III-1.
To avoid slross conconlralions, llo inlorior and oxlorior
Fig. III-1 eIect imensiens

150
cornors slouId bo maclinod vill a radius. Tlo odgo of
llo ropair slaII bo al Ioasl llroo limos llo pipo diamolor
avay from llo onds of llo pipo spooI.
Tlo losl prossuro of llo spooI,
, slaII bo dolorminod
by caIcuIalion using oq. (III-1)
(III-1)
A ropair Iaminalo slaII bo appIiod ovor llo dofocl in
llo losl spooI and slaII survivo a losl lo llo prossuro
.
Tlo llicInoss of llo ropair slaII bo caIcuIalod using
oq. (III-2), vloro
is llo romaining vaII llicInoss of

llo pipo spooI al llo dofocl and
is llo claraclorislic
lonsiIo slrongll of llo composilo ropair in llo loopdiroc-
lion. Moasuromonl of
slaII bo in accordanco vill

ASTM D 3039 or an oquivaIonl slandard.
ropair
(III-2)
Tlo ropairod spooI slaII bo prossurizod lo
. Tlo
minimum limo lo roacl
slaII bo 30 soc.
QuaIificalion roquiros llo ropairod pipo lo survivo
Ioading lo
and slov no visuaI signs of dogradalion

vlon inspoclod in accordanco vill TabIo 6 of ArlicIo 4.1.
III-3 kP0k1
A roporl slaII bo proparod giving llo losl condilions,
dopll of vaII Ioss for vlicl llo ropair las boonquaIifiod,
dolaiIs of llo Ropair Syslom, and llo prossuro losl rosuIl.

ArticIe 4.1, Mandatery Appendix Iv
Measurement eI Ier Leaking eIect CaIcuIatien
Iv-1 Ih1k0bC1I0h
Tlis Appondix doscribos llo losl mollod for moasuro-
monl of llo louglnoss paramolor for llo ropair Iaminalo-
lo-subslralo (pipo) inlorfaco, , lo bo usod in oqs. (12)
llrougl (14) in para. 3.4.6 of ArlicIo 4.1.
Iv-2 M1h0
Tosl pIalos or soclions of pipo of minimum diamolor
100 mm(4 in.) and minimumllicInoss of 3 mm (0.12 in.)
slaII bo usod. To roprosonl lypicaI dofocls, circuIar loIos
slaII bo driIIod llrougl llo vaII llicInoss of llo sub-
slralo and llo ropair Iaminalo appIiod. AII sampIos slaII
bo Iaminalod vill llo loIos in llo 6 ocIocI orionlalion.
Tlo pipo soclion usod for llo proparalion for llo losl
spocimon slaII bo approprialo for llo anlicipalod faiIuro
prossuro of llo ropair. YioIding of llo pipo prior lo faiIuro
slaII nol laIo pIaco.
InlornaI prossuro slaII bo appIiod and llo vaIuo al
vlicl llo ropair bogins lo IoaI slaII bo rocordod.
Tlo losl slaII bo carriod oul al llo lomporaluro al
vlicl llo ropair is lo bo usod.
Irossurizalion ralo slaII bo in accordanco vill ASTM
D 1599.
A minimum of nino losls slaII bo carriod oul covoring
a minimum of llroo difforonl loIo sizos, lypicaIIy of
diamolor 10 mm (0.4 in.), 15 mm (0.6 in.), and 25 mm
(1 in.). A maximum of ono-llird of llo losls slaII bo
dono for any ono loIo sizo.
Ior llo Iargor diamolors, llo fIav may bo simuIalod
by using a smaIIor loIo and a circuIar poIymoric roIoaso
fiIm of llo approprialo diamolor pIacod ovor llo loIo
prior lo appIicalion of llo ropair (fiIms slaII bo piorcod
boforo appIicalion of llo ropair).
IaiIuros slouId laIo llo form of disbondmonl of llo
ropair Iaminalo from llo subslralo (pipo) foIIovod by
IoaIing from llo odgo of llo ropair Iaminalo. Al smaII
loIo sizos, faiIuro can occur llrougl vooping of llo losl
fIuid llrougl llo llicInoss of llo ropair Iaminalo or
llrougl yioIding of llo subslralo (pipo). In llis ovonl
llo losls slaII bo ropoalod vill a Iargor loIo sizo. AII
faiIuro poinls slaII roIalo lo llo disbondmonl faiIuro
moclanism.
151
Iv-3 CALCbLA1I0h 0F
Tlo vaIuo of slaII bo caIcuIalod by filling oq. (12)
in para. 3.4.6 (ArlicIo 4.1) lo llo dala.
Tlo foIIoving procoduro slaII bo foIIovod:
llo funclion of dofocl sizo,
, and ropair Iam-

inalo proporlios of obsorvalion, , vloro
1,
llo numbor of obsorvod dala poinls |(
),
)]
llo prossuro al faiIuro of obsorvalion , vloro

1,
(
) is dofinod as

vloro

1
2
)
3
512
3
+
1
+
3
64
vloro
is llo ropair llicInoss of dala poinl .

Tlo moan onorgy roIoaso ralo,
moan
, is caIcuIalod from
moan
2
2
(IV-1)
Tlo Iovor confidonco Iimil of llo onorgy roIoaso ralo,
, is caIcuIalod from
ICI
2
2
(IV-2)

1abIe Iv-1 5tudent's vaIue Ier eubIe 5ided
0.025 LeveI eI 5igniIicance

5 3 3.163
6 / 2.969
7 5 2.8/1
8 6 2.752
9 7 2.685
10 8 2.63/
11 9 2.593
12 10 2.560
13 11 2.533
1/ 12 2.510
15 13 2./90
16 1/ 2./73
17 15 2./58
18 16 2.//5
152
vloro is llo varianco of moasuromonl of prossuro and
is givon by
moan
2
(
(IV-3)
and vloro
is llo Sludonls vaIuo and is basod on

a lvo-sidod 0.025 IovoI of significanco, i.o., 95 Iovor
confidonco Iimil. VaIuos of
aro givon as a funclion of

numbor of variabIos, , in TabIo IV-1.
Tlo vaIuo of caIcuIalod by oq. (IV-2),

slaII bo
usod in oqs. (12) llrougl (14) of ArlicIo 4.1.
Iv-4 kP0k1
dolaiIs of llo Ropair Syslom, llo individuaI dala poinls,
and llo dorivod vaIuo of

.
(08)

ArticIe 4.1, Mandatery Appendix v
Measurement eI PerIermance 1est ata
v-1 Ih1k0bC1I0h
Tlis Appondix doscribos llo losl mollods for moa-
suromonl of llo dosign aIIovabIos lo bo usod in para.
3.4.5 of ArlicIo 4.1. Tlo losl mollod aIlornalivos aro ono
of llo foIIoving:
survivaI losling vloro llo Ropair Syslom is sub-
joclod lo a poriod of suslainod Ioad for 1,000 lr for
moasuromonl of llo Iong-lorm slrongll
rogrossion losling basod on a sorios of losls on llo
Ropair Syslomovor difforonl limo poriods and oxlrapoIa-
lion lo dosign Iifo for moasuromonl of llo Iong-lorm
slrongll
coupon losling basod on rogrossion losling of rop-
rosonlalivo coupons foIIovod by confirmalion of Iong-
lorm coupon losl rosuIls vill survivaI losling for moa-
suromonl of llo Iong-lorm slrain
AII losls slaII bo carriod oul al llo maximumlompora-
luro al vlicl llo Ropair Syslom is lo bo usod in sorvico.
v-2 M1h05
v-2.1 5urvivaI 1esting
Soclions of pipo of minimum diamolor 100 mm (4 in.)
and minimum llicInoss of 3 mm (0.12 in.) slaII bo usod
and llo Ropair Syslom appIiod.
A vaIuo of inlornaI prossuro slaII bo appIiod (dofinod
by llo Ropair Syslom suppIior) and suslainod for
1,000 lr. If any dolorioralion of llo ropair Iaminalo in
llo form of cracIing, doIaminalion, or IoaIing occurs,
llo Ropair Syslom viII lavo faiIod llo losl. Tlroo idonli-
caI losls slaII bo porformod and ropair quaIificalion is
onIy possibIo if aII llroo losls survivo.
Tlo 95 Iovor confidonco Iong-lorm slross is caIcu-
Ialod using
losl

2(

min
+
)
(V-1)
If yioIding of llo subslralo pipo doos occur llon llo
95 Iovor confidonco Iong-lorm slross,
(MIa), is caI-
cuIalod using
(08)
ropair
(V-2)
Iurllor guidanco on survivaI prossuro losling proco-
duros may bo oblainod from ASTM D 1598.
153
v-2.2 kegressien 1esting
Soclions of pipo of minimum diamolor 100 mm (4 in.)
and minimum llicInoss of 3 mm (0.12 in.) slaII bo usod
and llo Ropair Syslom appIiod.
A sorios of losl spocimons slaII bo subjocl lo suslainod
prossuros of difforonl vaIuos. Tlo limo al vlicl llo
ropair Iaminalo slovs signs of dolorioralion dofinod as
cracIing, doIaminalion, or IoaIing slaII bo rocordod.
Tlo rosuIls slaII bo pIollod (Iog/Iog) and llo roquirod
prossuro dolorminod by a rogrossion anaIysis using llo
95 Iovor confidonco Iimil and oxlrapoIalion lo dosign
Iifo. Tlo convorsion from prossuro lo slross villin llo
ropair Iaminalo for oacl dala poinl slaII bo according lo

losl

2(

min
+
)
(V-3)
If yioIding of llo subslralo pipo doos occur llon llo
95 Iovor confidonco Iong-lorm slross,
(MIa), is caI-
cuIalod using
ropair
(V-4)
Al Ioasl 18 rosuIls aro roquirod in ordor lo carry oul
llo rogrossion anaIysis. ASTM D 2992 providos furllor
guidanco on llo Iong-lorm losling of composilo malori-
aIs and ISO 14692 providos guidanco on llo anaIysis of
llo dala roquirod lo caIcuIalo
.
v-2.3 kepresentative Ceupen 1esting
Roprosonlalivo coupons of llo ropair Iaminalo slaII
bo mado up and loslod in a comparabIo mannor lo llo
acluaI Ropair SyslomIaminalo. Roprosonlalivo impIios
samo Iaminalo consliluonls, voIumo fraclion, and fibor
orionlalion. ComparabIo Ioading impIios coupons
slaII bo Ioadod idonlicaIIy as llo in-sorvico ropair Iami-
nalo (o.g., uniaxiaI lonsion or biaxiaI lonsion).
Al Ioasl 18 coupons slaII bo loslod undor conslanl
Ioad lo faiIuro (dala poinls in lorms of numbor and
Iongll of limo of losling according lo ASTM D 2992, vill
llo slalislicaI anaIysis of dala according lo ISO 14692).
Oulpul of lloso coupon losls is llo rogrossion gradi-
onl, , in lorms of oillor Iog (slross or slrain) againsl
Iog (limo).
To dolormino llo Iong-lorm faiIuro slross or slrain of
llo Ropair Syslom, fivo modium lorm losls (according
lo ASTM D 1598) slaII bo porformod on soclions of pipo
of minimum diamolor 100 mm (4 in.) and minimum

llicInoss of 3 mm (0.12 in.). In lloso losls, llo prossuro
is fixod and llo limo lo faiIuro rocordod. Il is rocom-
mondod lo soIocl a losl prossuro so llal faiIuro occurs
aflor aboul 1,000 lr.
Tlo Iovor confidonco Iimil (in lorms of limo) for lloso
fivo losls is caIcuIalod according lo llo moan faiIuro limo
minus lvo slandard dovialions. Tlo Iong-lorm dosign
slrongll (or slrain) of llo Ropair Syslomis llo oxlrapoIa-
lion of llo Iovor confidonco Iimil lo llo dosign Iifolimo
using llo moasurod rogrossion gradionl from llo cou-
pon losls.
154
Iurllor guidanco on survivaI prossuro losling proco-
duros may bo oblainod from ASTM D 1598.
Iurllor guidanco on Iong-lorm losling and dala inlor-
prolalion may bo oblainod from ISO 14692.
v-3 kP0k1
and llo dorivod porformanco dosign dala.

ArticIe 4.1, Mandatery Appendix vI
Measurement eI Impact PerIermance
vI-1 Ih1k0bC1I0h
Tlis Appondix doscribos llo losl mollod for moasuro-
monl impacl porformanco. Tlo Ropair Syslom suppIior
slaII domonslralo llal llo ropair is capabIo of villsland-
ing llo impacl from a Iov voIocily 5 } (44.3 in.-Ib) impacl
roprosonlalivo of a droppod looI.
vI-2 M1h05
An idonlicaI losl spocimon lo ono of llo nino from
Mandalory Appondix IV (ArlicIo 4.1) slaII bo usod.
Tlo ropair slaII bo subjocl lo a 0.5 Ig (1.1 Ib) voigll
vill a 12 mm (0.5 in.) lomisploricaI indonlor droppod
from a loigll of 1 m (39 in.). Tlo pipo slaII bo supporlod
155
so llal llo loIo is in llo 12 ocIocI orionlalion and llo
voigll slaII slriIo llo ropair al llo posilion of llo loIo
in llo pipo. Tlo pipo slaII bo omply for llo duralion of
llo impacl losl.
Tlo impaclod spocimon slaII bo subjocl lo a prossuro
losl as doscribod in Mandalory Appondix IV (ArlicIo
4.1) . Tlo vaIuo of llo losl slaII bo caIcuIalod according
lo Mandalory Appondix IV. Tlo caIcuIalod vaIuo slaII
bo nol Ioss llan

.
vI-3 kP0k1
and llo dorivod porformanco.
(08)

ArticIe 4.1, Mandatery Appendix vII
InstaIIer uaIiIicatien
vII-1 Ih1k0bC1I0h
Tlo ropair of pipo using composilo Iaminalos diffors
considorabIy from ollor ropair loclniquos and llo quaI-
ily of llo inslaIIalion doponds slrongIy on salisfaclory
craflsmanslip. Training and corlificalion of porsonnoI
is lloroforo a Ioy oIomonl of a succossfuI ropair. Tlis
Appondix oulIinos llo minimum roquiromonls for lrain-
ing, quaIificalion, and approvaI of inslaIIors and suporvi-
sors for llo spocific Ropair Syslom.
Coursos and lraining slaII bo arrangod by or vill llo
assislanco of llo Ropair Syslom suppIior.
vII-2 1kAIhIhC
Tlo basic courso slaII givo a lloorolicaI and praclicaI
inlroduclion lo llo mosl imporlanl oIomonls in llo
inslaIIalion of a composilo ropair.
vII-2.1 Ceursewerk (InstaIIer)
Tlo courso slaII incIudo lraining in
dofinilion of a Ropair Syslom
lorminoIogy, lypos of ropair
lazards associalod vill prossurizod sysloms
loaIll, safoly, and onvironmonl
surfaco proparalion
maloriaI proparalion
maloriaI appIicalion
conlroI of ropair condilions
quaIily conlroI
vII-2.2 Ceursewerk (5uperviser)
Tlo suporvisor candidalo slaII bo a quaIifiod inslaIIor
and compIolo llo foIIoving addilionaI lraining:
suporvisors dulios and rosponsibiIilios
ovaIualion mollods usod in ropair dosign
loaIll and safoly
inslaIIalion clocIIisl and loId poinls
inspoclion of ropairs
156
vII-2.3 InstaIIer-5peciIic uaIiIicatien
InslaIIors slaII bo quaIifiod for oacl spocific Ropair
Syslomllrougl praclicaI losls for Typo Aand/or Typo B.
AII spocific approvaI losls slaII bo carriod oul in accor-
danco vill a vrillon procoduro, roIovanl lo llo spocific
Ropair Syslom and approvod by llo Ropair Syslom
suppIior.
vII-2.3.1 1ype A. Ropair slaII bo appIiod lo a pipo
of al Ioasl 100 mm (4 in.) diamolor. Ropair slaII pass
visuaI inspoclion compIolod in accordanco vill para.
5.2 of ArlicIo 4.1 vilnossod by a suporvisor or inslruclor.
vII-2.3.2 1ype . In addilion lo llo roquiromonls
for Typo A ropairs, an idonlicaI losl spocimon lo ono of
llo nino fromMandalory Appondix IV (ArlicIo 4.1) slaII
bo proparod. Tlo spocimon slaII bo subjocl lo a prossuro
losl as doscribod in Mandalory Appondix IV(soo ArlicIo
5.1 for guidanco). Tlo vaIuo of llo losl slaII bo caIcu-
Ialod according lo Mandalory Appondix IV. Tlo caIcu-
Ialod vaIuo slaII bo nol Ioss llan

.
vII-3 1kAIhIhC kC0k5
Al llo compIolion of an inslaIIor or suporvisor courso,
a succossfuI candidalo slaII bo issuod vill a corlificalo
providing dolaiIs of llo Ropair Syslom of concorn.
Tlo ompIoyor of llo Ropair SyslominslaIIor slaII Ioop
a rocord of llo compIolod lraining.
vII-4 vALII1
Tlo lypo-spocific quaIificalion slaII bo vaIid for a
poriod of 1 yoar.
Tlo quaIificalion may bo ronovod if llo appIicanl
providos ovidonco of succossfuI porformanco of ropairs
inslaIIod during llo provious yoar.
If llo inslaIIor las nol porformod a ropair in llo Iasl
yoar llon lloy slaII bo roquaIifiod prior lo appIying
furllor ropairs.
(08)

ArticIe 4.1, Mandatery Appendix vIII
InstaIIatien
vIII-1 Ih1k0bC1I0h
Ropair Syslom suppIiors slaII provido fuII inslaIIalion
inslruclions.
Tlo roquiromonls givon in llo foIIoving soclions aro
inlondod lo compIomonl lloso givon by Ropair Syslom
suppIiors and spocify llo Ioy oporalions nocossary for
a succossfuI ropair. In llo ovonl of confIicl, llo Ropair
Syslom suppIior slouId bo conlaclod for cIarificalion.
IuII inslruclions for oacl ropair silualion slaII bo
givon in llo mollod slal omonl proparod in oacl
inslanco.
vIII-2 5bkFAC PkPAkA1I0h
Tlo surfaco proparalion slaII oxlond al Ioasl ovor llo
vloIo surfaco onlo vlicl llo ropair Iaminalo is lo bo
appIiod and bo in accordanco vill llo spocific Ropair
Syslom.
Assossmonl of llo proparod surfaco for rouglnoss and
cIoanIinoss can bo oblainod from ISO 8501, ISO 8502,
ISO 8503, and ISO 8504.
Any clomicaIs usod for surfaco proparalion slaII bo
villin llo rocommondod sloIf Iifo, froslIy mixod (vloro
approprialo).
Tlo limo poriod bolvoon surfaco proparalion and ini-
liaI coaling/Iaminalo appIicalion slouId bo as slorl as
possibIo, lo avoid formalion of fIasl corrosion.
Iroparod surfacos slaII bo proloclod from conlamina-
lion prior lo llo appIicalion of llo ropair Iaminalo. Dolo-
rioralion of llo proparod surfaco slaII bo causo for
rojoclion and llo surfaco proparalion procoduro
ropoalod.
Tlo spocifiod surfaco proparalion loclniquo slaII nol
bo ropIacod by anollor, villoul oxpIicil guidanco from
llo Ropair Syslom suppIior, vlo slaII lavo quaIifiod
llo aIlornalivo as parl of a difforonl Ropair Syslom.
vIII-3 LAMIhA1 LA-bP
Wloro approprialo, lloso dolaiIs slaII incIudo
in-fiII compounds
primor appIicalion
poIymor/adlosivo proparalion
roinforcomonl orionlalion
ovorIaps bolvoon noiglboring vraps
157
ovorIaps bolvoon individuaI Iayors
consoIidalion of llo Iayors
finisling Iayor/coaling
lapor dolaiIs (soo para. 3.4.8 of ArlicIo 4.1)
vIII-4 Cbk
Sinco llo curo of a ropair Iaminalo is slrongIy infIu-
oncod by lomporaluro and llo corrocl mixing of poIymor
consliluonls prior lo Iaminalion, llo Iimils sol by Ropair
Syslom suppIior slaII nol bo oxcoodod villoul approvaI
from llo Ropair Syslom suppIior.
Wloro oIovalod lomporaluros aro roquirod for curing,
llo lomporaluro slaII bo monilorod llrougloul llo cur-
ing procoss and adloro lo Ropair Syslom suppIior s
guidanco.
Tlo limo for fuII curo is dopondonl on llo lypo of
poIymor usod in llo ropair and ambionl condilions. Tlo
oxlonl of curo acliovod during inslaIIalion slaII bo llo
samo as llal assumod in llo dosign.
If llo pipo prossuro las boon roducod prior lo ropair,
llon llo ropairod pipo slaII nol bo rolurnod lo ils normaI
oporaling prossuro unliI salisfaclory curo las boon
acliovod.
vIII-5 0CbMh1A1I0h
Il is good praclico lo Ioop a rocord for oacl ropair
and rolain il for llo ropair Iifo. Auniquo idonlifior slouId
bo assignod lo oacl ropair. Tlo rocords llal slouId bo
Iopl incIudo llo foIIoving:

Iayors and orionlalion of roinforcomonl
proparalion procoduro
curo procoduro
poslcuro
numbor of Iayors
axiaI oxlonl of ropair
dosign dala (Mandalory Appondix I of
ArlicIo 4.1) and caIcuIalions
Iocalion of ropair

ropair suppIior
poIymor lypo and quanlily
roinforcomonl lypo and quanlily
balcl numbors for maloriaIs
(08)
(08)

ropair roforonco numbor
visuaI inspoclion roporl (soo accoplabIo dofocls
Iislod in TabIo 6 of ArlicIo 4.1)
llicInoss moasuromonl
ropair dimonsions
158
porsonnoI compIoling llo inslaIIalion
BarcoI or Sloro lardnoss moasuromonl (if
spocifiod)

moasuromonl (if spocifiod)

DolaiIs of (fuluro) sorvico
inspoclion inlorvaIs.
(08)

ArticIe 4.1, Mandatery Appendix IX
CIessary eI 1erms and Acrenyms
IX-1 CL055Ak 0F 1kM5
oxlibiling difforonl proporlios in difforonl
diroclions.
moasuro of surfaco lardnoss using a sur-
faco improssor.
a llormosol pIaslic (poIymor) llal is roinforcod
by fibors.
unbroIon fibor Ionglls llrougloul llo
slrucluro.
solling of a llormosolling rosin, o.g., poIy-
oslor, opoxy, by an irrovorsibIo clomicaI roaclion.
soparalion of Iayors villin a composilo
Iaminalo or bolvoon llo Iaminalo and llo losl pipo.
mollod of
dolormining llo gIass lransilion lomporaluro of a llor-
mosolling rosin.
soparalion of llo Iaminalo from llo sub-
slralo (pipo).
lomporaluro al vlicl a rosin
undorgoos a marIod clango in plysicaI proporlios.
compononl addod lo an opoxy rosin lo affocl
curo.
lomporaluro al vlicl a slan-
dard losl bar dofIocls a spocifiod amounl undor a
givon Ioad.
maloriaI usod lo ropair oxlornaI surfaco
imporfoclions prior lo llo appIicalion of composilo
vrap.
llo parl of a Ropair Syslom llal is llo compos-
ilo. Mosl composilos considorod in llis documonl aro
composod of discrolo Iamina or Iayors, vlicl aro
vrappod or slacIod, ono on lop of llo ollor. Tlis slacIod
conslruclion is llo Iaminalo.
llis doos nol rofor lo a fIuid IoaIing llrougl a loIo
or broacl in llo pipo. Rallor, llis rofors lo a condilion
of a pipo (subslralo) vaII llal couId or doos aIIov llo
conlonls of a pipo lo maIo conlacl vill and acl diroclIy
upon llo (composilo) ropair Iaminalo.
llo company or onlily llal ovns or is rosponsibIo
for llo pipo subslralo boing ropairod.
pipo vill compononls (o.g., bonds, fIangos,
vaIvos) subjocl lo llo samo dosign condilions and lypi-
caIIy usod lo lransporl fIuids bolvoon pIanls, usuaIIy
buriod.
159
inlorconnoclod piping subjocl lo llo samo sol
or sols of dosign condilions.
assombIios of piping compononls (o.g., pipo, fil-
lings, fIangos, gasIols, boIling, vaIvos) usod lo convoy
fIuids villin a pIanl, oflon abovo ground bul somolimos
buriod.
a singIo vrap or Iayor (Iamina) of a ropair Iaminalo.
addilionaI oIovalod lomporaluro curo.
a ligl slrongll fibor imboddod in llo pIas-
lic rosin, rosuIling in moclanicaI proporlios suporior lo
lloso of llo baso rosin.
aII of llo compononls llal maIo up llo
malrix (pIaslic or poIymor) porlion of a composilo. Oflon
llis is a rosin, fiIIor(s), pigmonl, moclanicaI proporly
modifiors, and calaIysl or lardonor.
a lorm oncompassing vlal can lappon (sconario),
ils IiIoIilood (probabiIily), and ils IovoI of damago
(consoquoncos).
faco improssor or duromolor.
llo originaI pipo or pipo fillings lo bo modifiod.
llo company or onlily laIing rosponsibiIily for
losling and quaIifying a Ropair Syslom, usuaIIy llo man-
ufacluror, bul possibIy a providor of privalo-roIaboIod
producl.
lloso aro pIaslic rosins llal cannol bo ro-
soflonod foIIoving poIymorizalion.
IX-2 CL055Ak 0F ACk0hM5
Amorican IolroIoum Inslilulo
Tlo Amorican Socioly of MoclanicaI Inginoors
Amorican Socioly for Tosling and MaloriaIs
Amorican Walor WorIs Associalion
Brilisl Slandards Inslilulo
Carbon Iibor Roinforcod IIaslic
ConlroI of Subslancos Hazardous lo HoaIll
RoguIalions

Corlificalion Sclomo for WoIding Inspoclion
IorsonnoI
Iibor Roinforcod IIaslic
GIass Roinforcod IIaslic
Hoal Dislorlion Tomporaluro
160
InlornalionaI Slandards Organizalion
Maximum AIIovabIo WorIing Irossuro
MaloriaIs Safoly Dala Slools
Nondoslruclivo Tosling
OccupalionaI Safoly and HoaIll Acl
Spocifiod Minimum YioId Slrongll
(08)
(08)

ArticIe 4.2
henmetaIIic Cempesite kepair 5ystems Ier PipeIines and
Pipewerk: Lew-kisk AppIicatiens
1 5CkIP1I0h
1.1 5cepe
1.1.1 kepair kequirements. Tlis ArlicIo providos
llo roquiromonls for llo ropair of Iov-risI piping using
a quaIifiod Ropair Syslom.
1.1.2 eIinitien eI kepair 5ystem. Tlo Ropair
Syslom is dofinod as llo combinalion of llo foIIoving
oIomonls for vlicl quaIificalion losling las boon
compIolod:
subslralo (pipo)
surfaco proparalion
composilo maloriaI (ropair Iaminalo)
fiIIor maloriaI
adlosivo
appIicalion mollod
curing prolocoI
1.1.3 AIIewed MateriaIs. Tlo composilo maloriaIs
aIIovod for llo Ropair Syslomaro onginooring fibor (o.g.,
carbon, gIass) roinforcomonls in a llormosol poIymor
malrix (o.g., poIyoslor, poIyurollano, plonoIic, vinyI
oslor, or opoxy).
1.2 AppIicabiIity
1.2.1 xampIe AppIicatiens. Tlis ArlicIo addrossos
llo ropair of piping originaIIy dosignod in accordanco
vill a varioly of pipo slandards, incIuding ASMI B31.1,
ASMI B31.3, AWWA C200, AWWA C300, AWWA C301,
AWWAC302, AWWAC303, AWWAC400, AWWAC402,
ISO 15649, and ISO 13623.
1.2.2 eIinitien eI Lew kisk. Iov-risI appIicalions,
for llo purposos of llis ArlicIo, aro dofinod as lloso
appIicalions vloro aII of llo foIIoving appIy:
nonlazardous fIuids (o.g., aquoous fIuids)
piping sysloms nol crilicaI lo llo safoly of vorIors
(o.g., firo supprossion sysloms)
non-IDIH fIuids
Ioss llan 150 psig (1 MN/m
2
)
Ioss llan 120I (50C)

Ioss llan 78 in. (2 m) piping diamolor
llo IoaIing dofocl sizo, , and dosign prossuro, ,
salisfy llo foIIoving roIalionslip:
150 psig (in.)
0.5
161
0.5 MN/m
1.5
llo dofocl sizo slaII bo Iimilod lo 0.25
1.2.3 AppIicabIe eIects. Tlo foIIoving lypos of
dofocl may bo ropairod:
oxlornaI corrosion
oxlornaI damago
inlornaI corrosion and/or orosion
IoaIs
manufacluring or fabricalion dofocls
1.3 kisk Assessment
A dolorminalion slaII bo mado as lo vlollor llo
ropair is Iov risI, as dofinod in para. 1.2. Tlo risI assoss-
monl slouId dofino llo accoplabIo Iifo of llo ropair. An
assossmonl of llo risIs associalod vill llo dofocl and
ropair mollod slouId bo compIolod in Iino vill llo
roIovanl induslry bosl praclico.
NOTI: Soo ArlicIo 4.1 for guidanco in risI assossmonl.
Tlo informalion and dala doscribing any lazards
slaII bo incIudod in llo risI assossmonl lo bo usod on
silo.
1.4 kepair LiIe
Tlo ropair Iifo is llo usofuI sorvico poriod of llo Ropair
Syslom for a spocific appIicalion, vlicl may bo affoclod
by oxlornaI and onvironmonlaI oxposuros, aclivo inlornaI
corrosion/orosion, and oxlornaI moclanicaI infIuoncos.
Tlo ropair Iifo slaII bo dofinod by llo risI assossmonl.
2 LIMI1A1I0h5
2.2 uaIiIicatien eI kepair 5ystem
Tlo uso of llis ArlicIo is Iimilod lo lloso Ropair
Sysloms for vlicl llo quaIificalion losling doscribod in
Mandalory Appondix II las boon compIolod. Any
clango lo any oIomonl of llo Ropair Syslom (para. 1.1)
conslilulos a difforonl and lloroforo nov Ropair Syslom.
Tlis nov Ropair Syslom slaII roquiro quaIificalion as
doscribod in Mandalory Appondix II. Soo aIso para. 3.2.
(08)
(08)
(08)
(08)
(08)
(08)
(08)

2.3 InstaIIatien
Tlo inslaIIalion procoduros slaII bo lloso usod in llo
Ropair Syslom quaIificalion. If llo inslaIIalion proco-
duros aro nol lloso usod in llo Ropair Syslom quaIifica-
lion, llon llo ropair is nol in compIianco vill llis
ArlicIo.
2.4 Leading
If ollor Ioads aro prosonl villin llo ropair aroa, in
addilion lo inlornaI prossuro, llon ArlicIo 4.1 slaII bo
usod.
3 5ICh
3.1 5ymbeIs
Tloso aro llo symboIs usod llrougloul llis ArlicIo.
oxlornaI pipo diamolor, m (in.)
diamolor (or diamolor of llo oquivaIonl cir-
cIo) of llo dofocl or IoaIing rogion, m (in.)
dosign faclor

in llo circumforonliaI diroclion dolorminod
by losl according lo TabIo 1, N/m
2
(psi)
HDT loal dislorlion lomporaluro, C (I)
lolaI axiaI ropair Iongll, m (in.)
dofocl
axiaI Iongll of llo dofocl, mm (in.)
ovor
ovorIap Iongll, m (in.)
lapor
lapor Iongll, m (in.)
numbor of vraps as dolorminod by llo roIo-
vanl ropair dosign caso
minimum numbor of vraps for Typo A

ropairs
minimum numbor of vraps for Typo B

ropairs
minimum numbor of vraps for Typo C

ropairs
minimum numbor of vraps for Typo D

ropairs
ropair dosign prossuro, N/m
2
(psi)
vrap axiaI slrongll por pIy por molor (por

incl) in lonsion
vrap loop slrongll por pIy por molor (por

incl) in lonsion
dosign lomporaluro of Ropair Syslom, C

(I)
gIass lransilion lomporaluro, C (I)

vaII llicInoss of subslralo, m (in.)
3.2 kepair 5ystem uaIiIicatien ata
QuaIificalion of llo Ropair Syslom slaII bo com-
pIolod in accordanco vill TabIo 1 and Mandalory
Appondix II. IquivaIonl nalionaI or inlornalionaI pub-
Iislod losl mollods aro aIso accoplabIo.
MaloriaIs porformanco and losl dala slaII bo moa-
surod by a corlifiod or nalionaIIy accrodilod losl faciIily,
162
or corlifiod by a rogislorod IrofossionaI Inginoor (or
inlornalionaI oquivaIonl).
Tlo Ropair Syslom suppIior slaII spocify llo foI-
Ioving paramolors:
pipo maloriaI roslriclions
surfaco proparalion
ropair Iaminalo (poIymor malrix and fibor
roinforcomonl)
fiIIor maloriaI (dimonsionaI rosloralion), if usod
adlosivo/primor, if usod
appIicalion inslruclions
Any clango in llo abovo paramolors lo llo Ropair
SyslomslaII conslilulo a nov Ropair Syslomand roquiro
quaIificalion.
3.3 AdditienaI kequired ata
Tlo foIIoving dala slouId bo providod for oacl
ropair:
Iifolimo roquiromonls/oxpoclalion of llo ropair
sorvico Iifo
roquirod dosign and oporaling prossuros/
lomporaluros
oxpoclod fuluro sorvico condilions
piping Iino idonlily
doscriplion of llo piping, incIuding maloriaI
spocificalion and pipo vaII llicInoss
Tlo dala usod in llo dosign slaII bo rocordod.
Mandalory Appondix I may bo uliIizod.
3.4 CaIcuIatiens
Tlo dosign of llo ropair Iaminalo slaII bo carriod
oul using llo roquiromonls in llo foIIoving soclions.
Tloro aro four dosign casos:
Ior pipos llal aro nol IoaI-
ing (roquiring slrucluraI roinforcomonl onIy). Tlis slaII
bo caIcuIalod for aII ropairs.
Tlis slaII bo caIcuIalod for
pipos llal aro IoaIing.
pipo loos llal aro nol IoaIing.
pipo loos llal aro IoaIing.
A pipo slaII bo considorod lo bo IoaIing if llo vaII
llicInoss al any poinl of llo affoclod aroa is oxpoclod
lo bo Ioss llan 1 mm (0.04 in.) al llo ond of llo ropair
Iifo. Tlis slouId laIo accounl of aclivo inlornaI corrosion
vloro appIicabIo.
Ior oIbovs, bonds, roducors, and fIangos, llo
ropair llicInoss caIcuIalod in paras. 3.4.1 and 3.4.2 slaII
bo usod.
(08)
(08)

1abIe 1 kepair 5ystem kequired MateriaI and PerIermance Preperties

Mechanlcal prcpertles Tenslle prcpertles,
lSU 527 ASTM u 3039

Tenslle mcdulus,
. . .
6lass transltlcn temperature cf pclymer,
lSU 11357-2 ASTM u 660/, ASTM F 16/0,

cr ASTM F 831
Feat dlstcrtlcn temperature (FuT) lSU 75-1Ae cr lSU 75-18e ASTM u 6/8
8arccl hardness 8S Fh 59 ASTM u 2583
Shcre hardness lSU 868 ASTM u 22/0
Adheslcn strength Lap shear 8S Fh 1/65 ASTM u 3165
Leak seallng perfcrmance (cptlcnal) Mandatcry Appendlx lll
3.4.1 1ype A esign Case
Ior loop slrossos duo lo inlornaI prossuro, llo
minimum numbor of vraps,
, is givon by
(1)
vloro
is sol al 0.2 and
is laIon from TabIo 1.

Ior any casos vloro llo subslralo vaII llicInoss
las boon roducod by 50 or moro, llon llo foIIoving
caIcuIalion slaII bo mado:
(2)
min
, slaII bo
llo groalor of llo vaIuos dolorminod.
3.4.2 1ype esign Case. Tlo numbor of vraps,
, appIiod slaII bo llal quaIifiod in Mandalory

Appondix III.
3.4.3 1ype C esign Case. Ior loos, llo numbor of
Iayors,
, slaII bo 2
. Ior pipo loo joinls, llo diamolor

of llo Iargor pipo slaII bo usod in llo caIcuIalion.
3.4.4 1ype esign Case. Ior loos llal aro IoaIing,
llo numbor of Iayors,
, slaII bo llo groalor of
and
.
3.4.5 AxiaI Length eI kepair
Tlo dosign llicInoss of llo ropair Iaminalo slaII
oxlond boyond llo damagod rogion in llo pipo by
ovor
ovor
2.5 /2 (3)

ovor
slaII bo al Ioasl 0.05 m (2 in.).
Tlo onds of llo ropair may bo laporod. Aminimum
lapor Iongll,
lapor
, of approximaloIy 5:1 (run:riso) is
rocommondod.
163
Tlo lolaI axiaI Iongll of llo ropair is givon by
2
ovor
+
dofocl
+ 2
lapor
(4)
Tlo ropair slaII bo conlorod ovor llo dofocl.
3.4.6 nvirenmentaI CempatibiIity. Tlo suilabiIily
of llo Ropair Syslom for uso in llo sorvico onvironmonl
spocifiod by llo ovnor slaII bo dolorminod.
3.4.7 esign 0utput
Tlo oulpuls of llo dosign caIcuIalions of llo ropair
Iaminalo aro llo foIIoving:
llo numbor of vraps, , slaII bo dolorminod by
llo approprialo dosign caso spocifiod in para. 3.4 ( slaII
nol bo Ioss llan 2)
lolaI axiaI ropair Iongll,
Tlo Ropair SyslominslaIIor slaII bo providod vill
llo foIIoving informalion:
dolaiIs of Iaminalo Iay-up, incIuding numbor of
vraps, ropair aroa lo bo covorod, and orionlalion of
individuaI Iayors of roinforcomonl (llis may bo pro-
sonlod as a vrillon doscriplion or a draving incorporal-
ing slandard dolaiIs sucl as ovorIap and lapor)
dolaiIs of surfaco proparalion procoduro, incIud-
ing mollod of appIicalion, oquipmonl lo bo usod, and
inspoclion mollod
dolaiIs of in-fiII roquirod lo acliovo a smooll
oulor profiIo prior lo llo appIicalion of llo ropair
Iaminalo
dolaiIs of curo prolocoI
3.5 ApprevaI
Dosigns of ropairs according lo llis ArlicIo slaII bo
undorlaIon by a loclnicaIIy compolonl porson accopl-
abIo lo llo ovnor.
(08)
(08)
(08)
(08)

1abIe 2 heId Peints uring InstaIIatien

Materlals preparatlcn
relnfcrcement
pclymer
Surface preparatlcn
lnspectlcn
Flller prcflle
Stage check cn relnfcrcement lay-up
lnspectlcn cf repalr lamlnate
cure (hardness)
number cf wraps (thlckness)
dlmenslcns and pcsltlcn
external lnspectlcn (see Table 3)
Pressure test
3.6 kequaIiIicatien
Wloro lloro las boon a clango lo llo Ropair Syslom,
llon llo roIovanl losling spocifiod in para. 3.2 slaII bo
compIolod.
4.1 5terage Cenditiens
Slorago of maloriaI slouId compIy vill llo suppIi-
ors inslruclions.
Tlo MSDS slouId bo rolainod for roforonco.
Il slouId bo nolod llal llo maloriaIs usod viII
nood lo bo slorod and conlroIIod according lo nalionaI
safoly roguIalions (o.g., OSHA or COSHH).
4.2 InstaIIer uaIiIicatiens
IorsonnoI invoIvod in llo inslaIIalion of a Ropair
Syslom slaII bo lrainod and quaIifiod for llal Ropair
Syslom according lo Mandalory Appondix IV.
4.3 InstaIIatien Cuidance
Ropair Syslom suppIiors slaII provido inslaIIalion
inslruclions. Tloso inslruclions slaII incIudo (vloro
approprialo)
accoplabIo onvironmonlaI condilions of silo al
limo of ropair
maloriaI slorago
surfaco proparalion
poIymor mixing
Iaminalo Iay-up
Iaminalo consoIidalion
curo
Ioy loId poinls
Iurllor dolaiIs of lloso roquiromonls can bo found
in Mandalory Appondix V.
Tlo Ioy loId poinls llal may bo obsorvod during
a ropair aro summarizod in TabIo 2.
164
Tlo rosuIls from llo inspoclion of llo ropair Iami-
nalo slaII mool llo accoplanco criloria of llo dosign
oulpul.
4.4 Live kepairs
Ropairs lo nonIoaIing, Iivo piping sysloms aro possi-
bIo, providod llal llo associalod lazards aro fuIIy con-
sidorod in llo risI assossmonl for llo oporalion. Tlis
slouId incIudo any lazards lo and from surrounding
oquipmonl in addilion lo llo pipo boing ropairod.
5 XAMIhA1I0h
5.1 Intreductien
Tlis soclionprovidos guidanco on llo poslinslaIIa-
lion/oporalionaI issuos of Ropair Sysloms. Tlo
inslaIIalion of a Ropair Syslom viII nol advorsoIy affocl
any inlornaI inspoclions llal may bo carriod oul.
Tlo inspoclion of llo Ropair Syslom may incIudo
curo (lardnoss)
numbor of vraps (llicInoss)
dimonsions and posilion
oxaminalion for dofocls (soo TabIo 3)
Tlo basic slrucluro of a composilo ropair in llis
conloxl is iIIuslralod in Iig. 1 of ArlicIo 4.1.
5.2 eIects within the kepair 5ystem
Tlo Ropair Syslom suppIior slaII provido poslin-
slaIIalion visuaI oxaminalion criloria.
Guidanco on dofocls and aIIovabIo Iimils llal aro
IiIoIy lo bo of imporlanco aro givon in TabIo 3.
Tlo inslaIIor slaII laIo caro lo onsuro llal lloso
dofocls aro nol formod during appIicalion of llo Ropair
Syslom.
5.3 kepair eI eIects within the kepair 5ystem
Corroclivo aclions slaII bo as spocifiod by llo
Ropair Syslom suppIior lo addross llo dofocls idonlifiod
in TabIo 3.
Ropairs conlaining dofocls llal oxcood llo Iimils
in TabIo 3 slouId bo romovod and roappIiod. Hovovor,
on agroomonl vill llo ovnor, IocaI romovaI of llo dam-
agod aroa and roappIicalion of llo Ropair Syslommalori-
aIs lo llis aroa aro aIIovabIo if llo Ropair Syslom
suppIior can domonslralo llal llis viII rosloro llo fuII
porformanco of llo ropair.
6 551M Pk55bk 151IhC
Syslomprossuro losling, if roquirod, slaII bo spoci-
fiod by llo ovnor.
A sorvico losl of llo oporaling prossuro is
rocommondod.
Soo ArlicIo 5.1 for guidanco on prossuro losling.
Any signs of IoaIago or indicalion of ropair Iam-
inalo faiIuro slaII bo causo for rojoclion of llo ropair.
(08)
(08)
(08)
(08)

1abIe 3 eIect 1ype and AIIewabIe Limits Ier the Cempesite wrap

kepalr materlals and substrate Check that the materlals are thcse . . .
plpe prlcr tc repalr appllcatlcn speclfled by the ueslgn Uutput
Changes ln gecmetry kepalr area tc be free cf sharp changes ln gecmetry
|all radll 5 mm (0.2 ln.)[, cr sharp gecmetry tc
be smccthed. (Flller]ccntcur materlal)
Surface preparatlcn ln acccrdance wlth repalr system speclflcatlcn
Axlal extent tc be ln acccrdance wlth deslgn
Surface temperature ln acccrdance wlth repalr deslgn
uefect ulmenslcns dc nct exceed thcse fcr whlch the
repalr has been deslgned
uefect nature tc be that fcr whlch the repalr has
been deslgned
Lccatlcn cf repalr Axlal extent and pcsltlcnlng tc be ln acccrdance
wlth deslgn
lnterface uelamlnatlcn]dlsbcndlng Tap test may lndlcate presence cf delamlnatlcn cr
dlsbcndlng
hcne exlst at ends cf repalr
Pclymer-rlch layer Cracks hcne (check adheslve flllets)
Fcrelgn matter, bllsters, and plts Maxlmum 10 mm (0./ ln.) ln wldth, 2.5 mm
(0.1 ln.) ln helght
wrlnkles hc step changes ln thlckness greater than 2.5 mm
(0.1 ln.) ln helght
Pln hcles hcne deeper than pclymer-rlch layer
Pclymer cclcr unlfcrm
ury spcts hcne
Ccmpcslte lamlnate Flber crlentatlcn As speclfled ln deslgn
unlmpregnated]dry flber hcne
Fxpcsed, cut edges] flbers hcne
Fcrelgn matter hcne
Axlal extent and pcsltlcnlng cf the repalr As speclfled ln the deslgn
uces nct extend beycnd prepared surface
AII ropairs slaII bo curod in accordanco vill llo
Ropair Syslom suppIior inslruclions boforo prossuro
losling.
If llo losl prossuro oxcoods llo prossuro for vlicl
llo Ropair Syslom las boon dosignod, llon llo ropair
slaII bo rodosignod for llis liglor prossuro.
7 kFkhC5
ANSI/AII RI 579-2000, Iilnoss-Ior-Sorvico
(Rocommondod Iraclico)
165
ASMI B31G-1991, ManuaI: Dolormining Romaining
Slrongll of Corrodod IipoIinos: SuppIomonl To B31
Codo-Irossuro Iiping
ASTM D 648-2004, Slandard Tosl Mollod for DofIoclion
Tomporaluro of IIaslics Undor IIoxuraI Ioad in llo
Idgoviso Iosilion
ASTM D 1599-1999, Tosl mollod for slorl limo lydrau-
Iic faiIuro prossuro of pIaslic pipo, lubing and fillings
ASTM D 2240-2005, Slandard Tosl Mollod for Rubbor
Iroporly Duromolor Hardnoss
(08)

ASTM D 2583-1995, Slandard losl mollod for indonla-
lion lardnoss of rigid pIaslics by moans of a BarcoI
improssor
ASTM D 3165-2000, Slandard Tosl Mollod for Slrongll
Iroporlios of Adlosivos in Sloar by Tonsion Ioading
of SingIo-Iap-}oinl Iaminalod AssombIios
ASTM D 3681-2001, Slandard Tosl Mollod for ClomicaI
Rosislanco of IiborgIass (GIass-Iibor-Roinforcod
Tlormosolling Rosin) Iipo in a DofIoclod Condilion
ASTM D 5379-1998, Slandard Tosl Mollod for Sloar
Iroporlios of Composilo MaloriaIs by llo V-Nolclod
Boam Mollod
ASTM D 6604-2000, Slandard Iraclico for gIass lransi-
lion lomporaluros of Hydrocarbon Rosins by Difforon-
liaI Scanning CaIorimolry
ASTM I 831-2003, Slandard Tosl Mollod for Iinoar
TlormaI Ixpansion of SoIid MaloriaIs by
TlormomoclanicaI AnaIysis
ASTM I 1640-1999, Slandard Tosl Mollod for
Assignmonl of llo GIass Transilion Tomporaluro by
Dynamic MoclanicaI AnaIysis
Drivo, I.O. Box C700, Wosl ConslolocIon, IA
19428-2959
AWWA C200-97, Slandard for SlooI Walor Iipo 6 in.
(150 mm) and Iargor
AWWA C300-04, Roinforcod Concrolo Irossuro Iipo,
SlooI-CyIindor Typo
AWWA C301-07, Iroslrossod Concrolo Irossuro Iipo,
SlooI-CyIindor Typo
AWWA C302-04, Roinforcod Concrolo Irossuro Iipo,
NoncyIindor Typo
AWWA C303-02, Concrolo Irossuro Iipo, Bar-Wrappod,
SlooI CyIindor Typo
AWWA C400-03, Asboslos-Comonl Irossuro Iipo 4 in.
16 in. (100 mm400 mm) for Walor Dislribulion
Sysloms
AWWA C402-05, Asboslos-Comonl Transmission Iipo,
18 in. Tlrougl 42 in. (450 mm Tlrougl 1 050 mm)
for Walor SuppIy Sorvico
6666 Wosl Quuincy Avonuo, Donvor, CO 80235
166
BS IN 59-1977, Moasuromonl of lardnoss by moans of
a BarcoI improssor
BS IN 1465-1995, Dolorminalion of lonsiIo Iap sloar
slrongll of rigid lo rigid bondod assombIios
BS 7910-1999, Guido on mollods for assossing llo
accoplabiIily of fIavs in molaIIic slrucluros
IubIislor: Brilisl Slandards Inslilulo, Inc. (BSI), 12110
ISO 75-1993, IIaslics Dolorminalion of lomporaluro
of dofIoclion undor Ioad
ISO 178-2001, IIaslics Dolorminalion of fIoxuraI
proporlios.
ISO 527-1993, IIaslics Dolorminalion of lonsiIo
proporlios
ISO 868-2003, IIaslics and obonilo Dolorminalion of
indonlalion lardnoss by moans of a duromolor (Sloro
lardnoss)
ISO 8501-1988, Iroparalion of slooI subslralos boforo
appIicalion of painls and roIalod producls
ISO 8502-1992, Tosls for llo assossmonl of slooI
cIoanIinoss
ISO 8503-1988, Surfaco rouglnoss claraclorislics of bIasl
cIoanod slooI subslralos
ISO 8504-2000, Surfaco proparalion mollods
ISO 10952-1999, IIaslics piping sysloms GIass-
roinforcod llormosolling pIaslics (GRI) pipos and
fillings Dolorminalion of llo rosislanco lo clomicaI
allacI from llo insido of a soclion in a dofIoclod
condilion
ISO 11357-2-1999, IIaslics DifforonliaI scanning caIo-
rimolry (DSC) Iarl 2: Dolorminalion of gIass lransi-
lion lomporaluro
ISO 11359-2-1999, IIaslics TlormomoclanicaI anaIy-
sis (TMA) Iarl 2: Dolorminalion of coofficionl of
Iinoar llormaI oxpansion and gIass lransilion
lomporaluro
ISO 13623-2000, IolroIoum and naluraI gas induslrios
IipoIino lransporlalion sysloms
ISO 15649-2001, IolroIoum and naluraI gas induslrios
Iiping

kepair ata 5heet
Begins on next page.
167

168
(08)
(08)

uaIiIicatien ata
II-1 Ih1k0bC1I0h
Tlis Appondix doscribos llo quaIificalion dala
llal llo Ropair Syslom suppIior slaII provido lo bo in
compIianco vill llis ArlicIo.
Il is a roquiromonl llal aII quaIificalion losls aro
carriod oul using llo samo subslralo maloriaI, surfaco
proparalion, ropair Iaminalo, fiIIor maloriaI, adlosivo,
and appIicalion mollod (soo para. 1.1 of ArlicIo 4.2).
Any clango lo llo Ropair Syslom slaII conslilulo a nov
Ropair Syslom and roquiro quaIificalion.
QuaIificalion losling slaII bo compIolod in accor-
danco vill llo Ialosl vorsion of llo losl slandard.
Updalos lo llo losl slandards slaII nol roquiro quaIifica-
lion losling lo bo ropoalod.
II-2 A1A F0k kPAIk LAMIhA1
Tlo foIIoving dala aro roquirod:
lonsiIo slrongll por Iayor por molor (or slrongll
por Iayor por incl) in lonsion for loop diroclion (
)
and axiaI diroclion (
)
minimum lonsiIo moduIus (
) of 7 10
9
N/m
2
(1,000,000 psi)
BarcoI lardnoss or Sloro lardnoss dolorminod by
losl according lo TabIo 1 of ArlicIo 4.2 (if appIicabIo)
169
loal dislorlion lomporaluro (HDT) or llo gIass
lransilion lomporaluro (
) for llo Ropair Syslom slaII

bo groalor llan 60C (140I), dol orminod by losl
according lo TabIo 1 (ArlicIo 4.2)
II-3 A1A F0k kPAIk]PIP Ih1kFAC
Tlo Iap sloar losl slaII bo carriod oul according
lo TabIo 1.
Tlis slorl-lorm losl slaII bo usod lo dolormino
llo avorago sloar slrongll or llo Iocus of faiIuro.
Minimum avorago Iap sloar slrongll of
4 MN/m
2
(580 psi), or faiIuro of llo subslralo, slaII bo
domonslralod for aII subslralos.
AIlornalivoIy, il slaII bo domonslralod llal llo
adlosivo bond is slrongor llan llo sloar slrongll of llo
ropair Iaminalo or subslralo by assossing llo surfaco of
llo subslralo maloriaI usod in a Iap sloar spocimon aflor
losling.
II-4 AI1I0hAL kbIkMh15 F0k LAkIhC
PIP5
Tlo foIIoving dala aro roquirod: Domonslralion of
IoaI soaIing capacily, dolorminod by losl according lo
Mandalory Appondix III.
(08)
(08)
(08)

vaIidatien Ier kepair eI Leaking Pipe
III-1 Ih1k0bC1I0h
Tlis Appondix doscribos llo losling roquirod lo vaIi-
dalo llo Ropair Syslom for ropair of IoaIs.
Tlo Ropair Syslom slaII bo vaIidalod aflor llo
succossfuI compIolion of llroo losls on ono pipo sizo.
OnIy ono pipo sizo noods lo bo quaIifiod.
III-2 M1h0
Soclions of pipo of minimum diamolor 100 mm
(4 in.) and minimum llicInoss of 3 mm (0.12 in.) slaII
bo usod. A circuIar loIo of 25 mm (1 in.) diamolor slaII
bo driIIod llrougl llo vaII llicInoss of llo subslralo
and llo ropair Iaminalo appIiod. AII sampIos slouId bo
Iaminalod vill llo loIos in llo 6 ocIocI orionlalion.
170
Tlroo losls slaII bo compIolod al ambionl lomporaluro.
Tlo ropair llicInoss appIiod slaII bo caIcuIalod
using oq. (2) for a prossuro of 1 MN/m
2
(150 psig). Al
Ioasl lvo Iayors of roinforcing maloriaI slaII bo usod for
llo losl. Tlo loslod ropair llicInoss slaII bo dofinod
as
.
InlornaI prossuro slaII bo appIiod and llo ropair
slaII nol faiI boIov 3 MN/m
2
(450 psig). Irossurizalion
ralo slaII bo in accordanco vill ASTM D 1599.
III-3 kP0k1
dolaiIs of llo Ropair Syslom, and llo individuaI dala
poinls (finaI prossuro of losl).
(08)

InstaIIer uaIiIicatien
Iv-1 Ih1k0bC1I0h
Tlo ropair of pipo using composilo Iaminalos dif-
fors considorabIy from ollor ropair loclniquos and llo
quaIily of llo inslaIIalion doponds slrongIy on salisfac-
lory craflsmanslip. Training and corlificalion of porson-
noI is lloroforo a Ioy oIomonl of a succossfuI ropair.
Tlis Appondix oulIinos llo minimum roquiromonls for
lraining, quaIificalion, and approvaI of inslaIIors and
suporvisors.
Training slouId bo arrangod by or vill llo assisl-
anco of llo Ropair Syslom suppIior or ollor quaIifiod
lraining oxporl.
Iv-2 1kAIhIhC
Training slaII givo a lloorolicaI and praclicaI inlroduc-
lion lo llo mosl imporlanl oIomonls in llo inslaIIalion
of llo Ropair Syslom.
Iv-2.1 InstaIIer
Training slaII incIudo llo foIIoving:
dofinilion of a Ropair Syslom
lorminoIogy, lypos of ropair
lazards associalod vill prossurizod sysloms
loaIll, safoly, and onvironmonl
surfaco proparalion
maloriaI proparalion
maloriaI appIicalion
conlroI of ropair condilions
quaIily conlroI
171
Iv-2.2 5uperviser
Tlo suporvisor slaII bo a quaIifiod inslaIIor and com-
pIolo llo foIIoving addilionaI lraining:
suporvisors dulios and rosponsibiIilios
ovaIualion mollods usod in ropair dosign
loaIll and safoly
inslaIIalion clocIIisl and loId poinls
inspoclion of ropairs
Iv-2.3 InstaIIer-5peciIic uaIiIicatien
InslaIIors slaII bo quaIifiod for oacl spocific Ropair
Syslom llrougl praclicaI losls.
AII spocific approvaI losls slaII bo carriod oul in
accordanco vill roIovanl inslaIIalion procoduros.
Ropair slaII pass visuaI inspoclion compIolod in
accordanco vill para. 5.2 of ArlicIo 4.2 vilnossod by a
suporvisor or inslruclor.
Iv-3 kC0k 0F 1kAIhIhC
Tlo ompIoyor of llo Ropair Syslom inslaIIors slaII
Ioop rocords of lloir lraining.
Iv-4 bALIFICA1I0h PkI0
Tlo quaIificalion slaII romain vaIid for a poriod of
1 yoar foIIoving llo inslaIIalion of llo Iasl succossfuI
ropair.
(08)
(08)
(08)
(08)

ArticIe 4.2, Mandatery Appendix v
InstaIIatien
v-1 Ih1k0bC1I0h
Ropair SyslomsuppIiors slaII provido fuII inslaIIa-
lion inslruclions.
Tlo roquiromonls givon in llo foIIoving soclions
aro inlondod lo compIomonl lloso givon by Ropair
Syslom suppIiors and spocify llo Ioy oporalions nocos-
sary for a succossfuI ropair.
In llo ovonl of confIicl, llo Ropair Syslom suppIior
slouId bo conlaclod for cIarificalion.
v-2 5bkFAC PkPAkA1I0h
Tlo surfaco proparalion slaII oxlond al Ioasl ovor
llo vloIo surfaco onlo vlicl llo ropair Iaminalo is lo
bo appIiod and bo in accordanco vill llo spocific Ropair
Syslom.
Assossmonl of llo proparod surfaco for rouglnoss
andcIoanIinoss slouIdbo providod by llo Ropair Syslom
suppIior. Tlo spocifiod surfaco proparalion loclniquo
slaII nol bo ropIacod by anollor, villoul oxpIicil guid-
anco from llo Ropair Syslom suppIior, vlo slaII lavo
quaIifiod llo aIlornalivo as parl of a difforonl Ropair
Syslom.
Any clomicaIs usod for surfaco proparalion slaII
bo villin llo rocommondod sloIf Iifo, froslIy mixod
(vloro approprialo).
Tlo limo poriod bolvoon surfaco proparalion and
iniliaI coaling/Iaminalo appIicalion slouId bo as slorl
as possibIo (o.g., lo avoid formalion of fIasl corrosion).
Iroparod surfacos slaII bo proloclod fromconlaminalion
prior lo llo appIicalion of llo ropair Iaminalo. Doloriora-
lion of llo proparod surfaco slouId bo causo for rojoclion
and llo surfaco proparalion procoduro ropoalod.
v-3 LAMIhA1 LA-bP
Tlo spocific Ropair Syslom may nood lo incIudo
inslruclions for
in-fiII compounds
primor appIicalion
poIymor/adlosivo proparalion
consoIidalion of llo Iayors
172
finisling Iayor/coaling
lapor dolaiIs (soo para. 3.4.5 of ArlicIo 4.2)
v-4 Cbk
Sinco llo curo of a ropair Iaminalo may bo slrongIy
infIuoncod by lomporaluro and llo corrocl mixing of
poIymor consliluonls prior lo Iaminalion, llo Iimils sol
by Ropair SyslomsuppIior slaII nol bo oxcoodod villoul
approvaI from llo Ropair Syslom suppIior.
Tlo limo for fuII curo is dopondonl on llo lypo of
poIymor usod in llo ropair and ambionl condilions.
If llo pipo prossuro las boon roducod prior lo
ropair, llon llo ropairod pipo slaII nol bo rolurnod lo
ils normaI oporaling prossuro unliI salisfaclory curo las
boon acliovod.
v-5 0CbMh1A1I0h
Il is good praclico lo Ioop a rocord for oacl ropair
and rolain il for llo ropair Iifo.
A uniquo idonlifior may bo assignod lo oacl ropair.
Tlo rocords llal may bo Iopl incIudo llo foIIoving:

Iayors and orionlalion of roinforcomonl
proparalion procoduro
curo prolocoI
numbor of Iayors
axiaI oxlonl of ropair
dosign dala (Mandalory Appondix I of
ArlicIo 4.2) and caIcuIalions
Iocalion of ropair

ropair suppIior
poIymor lypo and quanlily
roinforcomonl lypo and quanlily
balcl numbors for maloriaIs

ropair roforonco numbor
visuaI inspoclion roporl (soo TabIo 3 of
ArlicIo 4.2)
llicInoss moasuromonl
ropair dimonsions
porsonnoI compIoling llo inslaIIalion
BarcoI or Sloro lardnoss moasuromonl (if
spocifiod)
(08)
(08)
(08)

ArticIe 4.2, Mandatery Appendix vI
vI-1 CL055Ak 0F 1kM5
faco improssor.
a llormosol pIaslic (poIymor) llal is roinforcod
by fibors.
solling of a llormosolling poIymor, o.g.,
poIyoslor, opoxy, by an irrovorsibIo clomicaI roaclion.
soparalion of Iayors villin a composilo
Iaminalo.
mollod of
dolormining llo gIass lransilion lomporaluro of a llor-
mosolling poIymor.
soparalion of llo Iaminalo from llo sub-
slralo (pipo).
lomporaluro al vlicl a poIy-
mor undorgoos a marIod clango in plysicaI proporlios.
compononl addod lo a rosin lo affocl curo of
llo llormosol poIymor.
lomporaluro al vlicl a slan-
dard losl bar dofIocls a spocifiod amounl undor a
givon Ioad.
maloriaI usod lo ropair oxlornaI surfaco
imporfoclions prior lo llo appIicalion of composilo
vrap.
llo parl of a Ropair Syslom llal is llo compos-
ilo. Mosl composilos considorod in llis documonl aro
composod of discrolo Iamina or Iayors, vlicl aro
vrappod or slacIod, ono on lop of llo ollor. Tlis slacIod
conslruclion is llo Iaminalo.
llis doos nol rofor lo a fIuid IoaIing llrougl a loIo
or broacl in llo pipo. Rallor, llis rofors lo a condilion
of a pipo (subslralo) vaII llal couId or doos aIIov llo
conlonls of a pipo lo maIo conlacl vill and acl diroclIy
upon llo (composilo) ropair Iaminalo.
llo company or onlily llal ovns or is rosponsibIo
for llo pipo subslralo boing ropairod.
pipo vill compononls (o.g., bonds, fIangos,
vaIvos) subjocl lo llo samo dosign condilions and lypi-
caIIy usod lo lransporl fIuids bolvoon pIanls, usuaIIy
buriod.
inlorconnoclod piping subjocl lo llo samo sol
or sols of dosign condilions.
173
assombIios of piping compononls (o.g., pipo, fil-
lings, fIangos, gasIols, boIling, vaIvos) usod lo convoy
fIuids villin a pIanl, oflon abovo ground bul somolimos
buriod.
a singIo vrap or Iayor (Iamina) of a ropair Iaminalo.
aII of llo compononls llal maIo up llo
malrix (pIaslic or poIymor) porlion of a composilo. Oflon
llis is a rosin, fiIIor(s), pigmonl, moclanicaI proporly
modifiors, and calaIysl or lardonor.
a ligl slrongll fibor imboddod in llo poIy-
mor, rosuIling in moclanicaI proporlios suporior lo lloso
of llo baso poIymor.
a lorm oncompassing vlal can lappon (sconario),
ils IiIoIilood (probabiIily), and ils IovoI of damago
(consoquoncos).
faco improssor or duromolor.
llo originaI pipo or pipo compononl lo bo
modifiod.
llo company or onlily laIing rosponsibiIily for
losling and quaIifying a Ropair Syslom, usuaIIy llo man-
ufacluror, bul possibIy a providor of privalo-roIaboIod
producl.
lloso aro pIaslics llal cannol bo ro-
soflonod foIIoving poIymorizalion.
vI-2 CL055Ak 0F ACk0hM5
Brilisl Slandards Inslilulo
ConlroI of Subslancos Hazardous lo HoaIll
RoguIalions
GIass Roinforcod IIaslic
Hoal Dislorlion Tomporaluro
ImmodialoIy dangorous lo Iifo or loaIll
InlornalionaI Organizalion for Slandardizalion
MaloriaIs Safoly Dala Slools
OccupalionaI Safoly and HoaIll Acl
(08)

ArticIe 4.3
henmetaIIic InternaI Lining Ier Pipe:
5prayed Ferm Ier uried Pipe
1 5CkIP1I0h
1.1 ackgreund
Tlis ArlicIo is for uso of llormosol poIymors as proloc-
livo or slrucluraI Iining for buriod pipo vlon appIiod
in a sprayod form (soo Iig. 1). Tlo pipo can bo slooI,
casl iron, concrolo, or ollor maloriaIs, Iocalod boIov
ground/buriod, and vill/villoul Iinors (o.g., comonl,
painl). Wlon using llormosol poIymors, llo ropair is
commonIy caIIod Curod-In-IIaco Iipo (CIII). Tlis
ArlicIo doos nol appIy lo abovo-ground piping, pumps,
vaIvos, lanIs, or prossuro vossoIs.
Uso of CIII ropair mollods can provido addod slruc-
luraI slrongll, incroasod clomicaI and abrasion rosisl-
anco, roducod infiIlralion and oxfiIlralion, and roducod
pipoIino fIov rosislanco. Tlis ropair mollod is parlicu-
IarIy usofuI for buriod piping groalor llan 600 mm
(24 in.) diamolor.
Tlo sprayod form appIicalion of nonmolaIIic inlornaI
Iining can bo considorod llo in-pIaco formalion of a
composilo pipo.
Ipoxios aro porlaps llo bosl of llo llormosol poIy-
mors for buriod pipo rolabiIilalion duo lo lloir vorsaliI-
ily, slrongll, adloronco lo llo losl pipo, Iov coofficionl
of friclion, and clomicaI and abrasion rosislanco.
1.2 Advantages
IroporIy appIiod onlo llo insido of llo losl pipo, llo
poIymor adloros voII lo llo pipo and bocomos parl of
a composilo syslom (poIymor Iining pIus llo losl pipo).
Tlo poIymor can bo roinforcod vill cloppod fibor (i.o.,
gIass, carbon), fibor cIoll, proimprognalod carbon, or
puIlrudod carbon, lloroby maIing llo composilo pipo
mucl slrongor. Tlo poIymor spray form ropair syslom
can bo manuaIIy usod for palcling porlions of llo buriod
pipo insload of llo onliro buriod pipo. Il is roIalivoIy
oasy lo appIy vloro llo pipo sizo pormils man onlry.
1.3 isadvantages
Tlis ropair mollod is moro difficuIl lo appIyfor buriod
pipo Ioss llan DN 600 (NIS 24) in diamolor, sinco
mannod pipo onlry and spraying is praclicaIIy impossi-
bIo for normaIIy sizod individuaIs. Tloro is llo possibiI-
ily of appIying llo sprayod form ropair syslom in smaII
pipos by romoloIy-oporalod robols. Tlis is avaiIabIo for
spociaIizod appIicalions.
174
2 CAb1I0h5 Ah LIMI1A1I0h5
2.1 CeneraI
2.2 AppIicatien 1emperature Limitatiens
Tlo llormosol poIymors maximum and minimum
dosign lomporaluro Iimilalions slaII bo considorod for
llo spocific appIicalion, sinco llo maloriaI proporlios
aro subslanliaIIy affoclod abovo llo
(gIass lransilion
lomporaluro) or
(loal dislorlion lomporaluro).

2.3 0perating 1emperature Limitatiens
Tlo llormosol poIymors maximum and minimum
oporaling lomporaluro slaII bo considorod for llo spo-
cific appIicalion, sinco llo poIymor porformanco
doponds groalIy on ils composilion. Boyondllal lompor-
aluro, llo sorvico Iifo of llis ropair mollod can bo sub-
slanliaIIy slorlonod.
2.4 AppIicatien humidity Limitatiens
Tlo llormosol poIymors bond lo llo pipo subslralo
is affoclod by appIicalion lumidily. Tlo appIicalion
lumidily roquiromonls slaII bo idonlifiod
for poIymors llal uso soIvonls for llo appIicalion
procoss, sinco lumidily can affocl llo drying procoss
for appIicalions llal nood ligl bond slrongll lo
llo pipo subslralo, sinco ligl lumidily can causo rapid
oxidalion (i.o., fIasl rusl). Tlis is parlicuIarIy an impor-
lanl paramolor for aIuminum and iron pipo.
Tlus, lumidily villin llo appIicalion aroa noods lo
bo conlroIIod, as rocommondod by llo manufacluror.
2.5 AppIicatien 5urIace Limitatiens
Tlo offoclivo formalion of a composilo pipo roquiros
llal llo Iining adloro lo llo losl pipo. Tlo Iining adlor-
onco is sonsilivo lo llo surfaco cIoanIinoss and llo surfaco
profiIo.
2.6 AppIicatien Curing Limitatiens
Tlo curing for llormosol poIymors is limo/lompora-
luro sonsilivo. Tlo curing procoss for Iovor appIicalion
lomporaluros may roquiro auxiIiary loal lo avoid
oxlromoIy Iong curo limos.

Fig. 1 5tructuraI Liner In kaw water 5ystem
3 5ICh
3.1 CeneraI esign Censideratiens
Tloro aro llroo dosign appIicalion calogorios for CIII
ropair.
pipo corrosion
proloclion Iinor from llo conlainod fIuid (nonIoad
boaring)
Tlo CIII appIicalion is assumod lo carry no
syslom Ioads.
Tlo Iinor slaII bo sizod lo provido proloclivo
barrior lo furllor dogradalion.
Ioad-boaring
mombor for a syslom villin a parliaIIy dolorioralod
buriod pipo
Tlis ArlicIo appIios lo conlinuousIy supporlod
buriod piping sysloms vloro llo dogradod losl pipo
sliII las sufficionl slrongll lo carry a porlion of llo soiI,
surfaco, and inlornaI prossuro Ioads.
Tlo Iinor slaII bo sizod lo rosisl llo oxlornaI
groundvalor lydroslalic Ioad.
Ioad-boaring
mombor for a syslom villin a fuIIy dolorioralod bur-
iod pipo
175
Tlis ArlicIo appIios vlon llo buriod losl pipo
las insufficionl slrucluraI capacily lo carry llo soiI, sur-
faco, and prossuro Ioads and sorvos onIy as a form for
CIII appIicalion.
Tlo Iinor slaII bo sizod lo landIo aII appIicabIo
Ioads.
3.2 1ypes eI 5prayed Ferm
3.2.1 PeIymer 5ystem. Tlo sprayod formropair sys-
lomslaII consisl of poIymor appIicalion, vill or villoul
roinforcing fibor. Tlo roinforcing fibor may bo cloppod,
cIoll, parliaIIy curod, or puIlrudod maloriaIs. Tlo
sprayod form may uso a varioly of roinforcing fibors (i.o.,
gIass, carbon, KovIar). TypicaIIy llo poIymor rosin and
curing agonl is mixod on-silo, pumpod llrougl a spray
nozzIo, and appIiod diroclIy lo llo inlornaI pipo surfaco
boing proloclod or roinforcod. Tlo poIymor may bo man-
uaIIy mixod, llo fibor manuaIIy vollod, and llo combi-
nalion poIymor-fibor malrix manuaIIy appIiod lo llo
pipo I.D.
3.2.2 CIPP esign variabIes. Tlo CIII dosign slaII
considor llo foIIoving for llo spocific appIicalion:
syslom oxposuro (i.o., acids, soIvonls, valor)

oporaling lomporaluros (maximum, minimum,
and rango)
coofficionls of llormaI oxpansion
moduIus of oIaslicily
lonsiIo slrongll
3.3 Piping egradatien Cases
Iaragrapls 3.3.1 llrougl 3.3.5 provido llo rocom-
mondod dosign appIicalion calogory llal slouIdbo usod
vill llo fivo dogradalion caso sconarios. AIlornalivoIy,
ollor filnoss-for-sorvico slandards (sucl as AII RI 579,
ASMI B31G, or ASMI IIS-1) may bo usod lo dolormino
if ollor dosign appIicalion calogorios may bo ompIoyod,
or if ropairs aro ovon nocossary.
3.3.1 Piping egradatien, Case #1. Caso #1 is vloro
inlornaI corrosion las nol yol occurrod or las ponolralod
Ioss llan llo dopll of llo accoplod corrosion aIIovanco.
In llis caso, llo losl pipo mools aII of llo nocossary
dosign roquiromonls. Tlo appIicalion of a proloclivo
CIII Iining may oxlond llo dosign Iifo of llo losl pipo
lo romain salisfaclory for llo Iifo of llo pIanl. Tlis Caso
is a good appIicalion of dosign appIicalion Calogory A.
inlornaI corrosion is vory IocaIizod, sucl as pilling corro-
sion. Somo pin loIo IoaIs may bo ovidonl. Will llo
oxcoplion of lloso smaII aroas, llo losl pipo las nol Iosl
ils corrosion aIIovanco. Tlo Iossos in lloso smaII aroas
do nol affocl llo gonoraI ovoraII slrongll of llo losl pipo
and do nol indicalo any noar lorm imponding faiIuro.
Tlo ropair of lloso IocaIIy corrodod aroas viII aIIov llo
losl pipo lo romain salisfaclory unliI llo noxl roquirod
inspoclion. Tlis Caso is a good appIicalion of dosign
appIicalion Calogory B.
lloro is sovoro corrosion, Iimilod lo slorl Ionglls or
soclions of losl pipo. Tlis gonoraI corrosion migll lavo
boon causod by Ioss or damago lo llo originaI Iinor,
fIavs in llo losl pipo, poorIy conlroIIod voId maloriaI,
or Ioss of callodic proloclion. Tlo Iossos duo lo llis
gonoraIizod corrosion aro groalor llan llo corrosion
aIIovanco and somo dogroo of faiIuro of llo losl pipo
migll bo ominonl. Tlis Caso is a good appIicalion of
dosign appIicalion Calogory B.
lloro is significanl gonoraIizod inlornaI corrosion. Tlo
losl pipo las Iosl aII or mosl of ils corrosion aIIovanco.
Tlo losl pipo sliII mainlains llo majorily of ils roquirod
slrongll and is undor no immodialo dangor of cala-
slroplic faiIuro. Tlis Caso is a good appIicalion of dosign
appIicalion Calogory B or C.
lloro is sovoro gonoraIizod corrosion, oillor inlornaI,
oxlornaI, or a combinalion. Tlo losl pipo is in immodialo
dangor of faiIuro. Tlo losl pipo can no Iongor bo
176
oxpoclod lo carry llo majorily of llo dosign Ioads. Tlo
losl pipo may conlinuo lo undorgo oxlornaI corrosion
ovon if a CIII Iinor is inslaIIod. Tlis Caso is a good
appIicalion of dosign appIicalion Calogory C.
3.4 MateriaI Censideratiens
Tlis ArlicIo lypicaIIy appIios lo llormosol poIy-
mors llal may lavo roinforcing fibor.
Tlo llicInoss of llo appIiod llormosol poIymor
(and amounl/lypo of roinforcing fibor) slaII dopond on
vlollor llo maloriaI is lo provido proloclivo Iining lo
pipo (dosign appIicalion Calogory A), lo slrucluraIIy
augmonl llo parliaIIy dolorioralod losl pipo (dosign
appIicalion Calogory B), or lo carry aII llo dosign Ioads
of llo pipo (dosign appIicalion Calogory C).
IoIymor mixing ralios, solling limo, and curing
limo slaII compIy vill llo manufacluror spocificalions.
3.5 MateriaI Preperty eterminatien
Tlo dosign Iifo and llo maximum/minimum lom-
poraluros lo vlicl CIII viII bo oxposod ovor ils dosign
Iifo for aII anlicipalod Ioading condilions slaII bo spoci-
fiod. MaloriaI proporlios slaII bo providod by llo
Manufacluror. NormaIIy llo Manufacluror las a varioly
of llormosol poIymors lo fil villin llo appIicalion
noods.
MaloriaI losling is addrossod in para. 5.2.
A limo-lomporaluro-corroclod fIoxuraI moduIus of
oIaslicily slaII bo dol orminod in accordanco vill
ASTM D 790 or ISO 178 using llo maximum lompora-
luro and dosign Iifo from para. 3.5.1.
A limo-lomporaluro-corroclod uIlimalo lonsiIo
slrongll slaII bo dolorminod in accordanco vill
ASTM D 638, ASTM D 3039, or ISO 527 using llo
maximum/minimum lomporaluro and dosign Iifo from
para. 3.5.1.
Tlo Iong-lorm croop porformanco of llo maloriaI
may bo dolorminod in accordanco vill ASTM D 2990
or BS IN 899-2.
Tlo coofficionl of llormaI oxpansion for llo maxi-
mum and minimum lomporaluros from para. 3.5.1 slaII
bo dol orminod in accordanco vill ASTM D 696,
ASTM I 831, or ISO 11359.
Tlo puII-off slrongll (adlosion) may bo dolor-
minod in accordanco vill ASTM D 3983.
Tlo Iap sloar slrongll may bo dolorminod in
accordanco vill ASTM D 3165 or BS IN 1465.
Tlo pooI or slripping slrongll may bo dolorminod
in accordanco vill ASTM D 903.
Tlo abrasion rosislanco may bo dolorminod in
accordanco vill ASTM D 4060 or CS 17.
Tlo impacl slrongll may bo dolorminod in accor-
danco vill ASTM G 14.
3.6 5peciIic esign kequirements
3.6.1 esign 1hickness. Tlo dosign llicInoss of llo
CIII is a funclion of llo poIymor, roinforcing maloriaI,

and dosign appIicalion calogory (A, B, or C). Tlo anlici-
palod or posluIalod Ioads slaII bo spocifiod in llo dosign
spocificalion for llo piping syslom modificalions.
3.6.2 esign 5peciIicatien kequired Leads. Tlo
dosign spocificalion slaII addross llo foIIoving Ioads:
InlornaI prossuro
is lypicaIIy llo firsl dosign considoralion for buriod pipo.
Having soIoclod a pipo maloriaI and diamolor compali-
bIo vill llo roquirod fIov, llo dosignor caIcuIalos llo
minimum vaII llicInoss roquirod lo safoIy suslain llo
dosign prossuro al llo dosign lomporaluro. Tlo oqualion
usod lo caIcuIalo llo vaII llicInoss of buriod piping is
spocifiodin llo codo or slandard appIicabIo lo llo sorvico
(soo soclion 7 for roforoncos). In aII casos, llo inlonl of
llo oqualion for vaII llicInoss is lo Iimil llo loop slross
in llo losl pipo (originaI dosign), composilo pipo, or
CIII lo a fraclion of llo maloriaIs spocifiod minimum
yioId or uIlimalo slrongll. Tlo form of llo oqualion for
llo originaI dosign varios vill llo appIicabIo codo and
pipo maloriaI, bul il is nol difforonl llan llo
abovo-ground prossuro dosign oqualion (pipo vaII is
sizod llo samo vay for undorground and abovo-ground
sorvico). Ior dosign appIicalion Calogorios B and C, llo
CIII slaII accommodalo llo syslom dosign prossuro.
Soo Mandalory Appondix I for appIicabIo oqualions
for CIII.
SoiI Ioads aro an imporlanl
considoralion for pipos mado of rigid and nonducliIo
maloriaIs sucl as concrolo or casl iron and pipos vill
Iargo / sucl as oncounlorod in civiI onginooring appIi-
calions. ConvorsoIy, oarll Ioads aro raroIy quanlifiod for
prossuro piping mado of ducliIo maloriaIs sucl as slooI
or poIyollyIono. Ior dosign appIicalion Calogory C, llo
CIII slaII villsland llo soiI Ioad. Soo Mandalory
Appondix I for appIicabIo oqualions for CIII.
Tlo offocl of loavysurfaco
Ioads, sucl as liglvay lraffic, raiIroad, or slrucluros
buiIl abovo llo buriod pipo docroasos as llo squaro of
llo loigll of soiI covors and is oflon conlroIIod by pro-
viding a minimum dopll of covor abovo llo pipo.
Minimum dopll of covors aro spocifiod by codos and
slandards and slouId bo vorifiod by anaIysis for parlicu-
IarIy loavy surfaco Ioads. Ior dosign appIicalion
Calogory C, llo CIII slaII villsland llo surfaco Ioad.
Soo Mandalory Appondix I for appIicabIo oqualions
for CIII.
Buriod pipoIinos
aro oflon oporalod al lomporaluros llal aro nol signifi-
canlIy abovo llo surrounding soiI lomporaluro. If lloro
is no difforonliaI oxpansion bolvoon llo soiI and llo
pipo, llon a llormaI anaIysis is nol roquirod. In casos
vloro llo fIuid is lol, comprossivo and bonding slrossos
aro gonoralod as llo pipo oxpansion is roslrainod by
llo surrounding soiI, unIoss a minoraI fibor cuslion (or
oquivaIonl) las boon vrappod around oIbovs and bonds
177
lo pormil llormaI oxpansion. Soo Mandalory Appondix
I for appIicabIo oqualions for CIII.
3.6.3 esign 5peciIicatien 0ptienaI Leads. Tlo
dosign spocificalion slouId considor llo foIIoving Ioads:
Tlo rosponso of a buriod
pipo lo valorlammor diffors from llo bolavior of
abovo-ground piping, sinco il is roslrainod by soiI llal
Iimils ils movomonls and bonding momonls. Undor llo
oxcossivo loop slrossos from llo prossuro puIsos llal
accompany valorlammor, filling, vaIvo, or pipo, rupluro
is possibIo.
In praclico, llo dosign
of buriod pipo for soismic Ioads is Iimilod lo crilicaI
appIicalions in oarllquaIo prono aroas. An oarllquaIo
may affocl llo inlogrily of a buriod pipo in lvo possibIo
vays: llrougl vavo passago (lransionl ground doforma-
lion) and llrougl pormanonl ground doformalion. IaiI-
uros in voIdod slooI pipos aro moro oflon duo lo soiI
faiIuros (Iiquofaclion, IandsIidos, fauIl movomonl) rallor
llan llo lransionl passago of soismic vavos.
Ollor appIicabIo Ioads
slouId bo considorod (i.o., abrasion, impacl).
4.1 hest Pipe xaminatien and Preparatien
4.1.1 5eundness xaminatien. A soundnoss oxami-
nalion slaII bo porformod lo dolormino llo dosign condi-
lion of llo losl pipo, i.o., parliaIIy or fuIIy dolorioralod.
4.1.2 5aIe werking Cenditiens. Safo vorIing condi-
lions slaII bo oslabIislod incIuding
idonlificalion of maloriaIs lo bo landIod, incIuding
copios of MSDS.
appIicabIo safoly roguIalions (o.g., OSHA) assoss-
monl for llo procoss.
spocifying dolaiIs of porsonaI proloclivo moasuros
lo bo adoplod.
Iisling of lazards associalod vill pipo boing
ropairod and oquipmonl in llo vicinily of llo ropair silo
vill proloclivo moasuros. Nolo llal for a fuIIy dolorio-
ralod pipo, spociaI safoly procaulions may bo nocossary
prior lo porsonnoI onlry inlo llo pipo.
4.1.3 5urIace Preparatien. Tlo inlorior of llo losl
pipo slaII bo cIoanod of Iooso rusl, scaIo, and biofouIing.
Ior bosl adlosion of llo llormosol poIymor lo llo losl
pipo, llo insido pipo surfaco slaII bo proparod lo
SSIC-SI-10/NACI 2 noar-vlilo-bIasl cIoaning condi-
lion or lo ASTM D 4258 for concrolo pipo.
4.2 PeIymer Mixing
Rosin and curing agonl balclos and mixluro propor-
lion slaII bo vorifiod, por llo manufacluror s
rocommondalions.

4.3 PeIymer AppIicatien
IoIymor slaII bo appIiod in ovon and ovorIapping
pallorns unliI dosign llicInoss is acliovod.
Wlon roinforcing fibors aro addod, lloy slaII bo
ovonIy disporsod, vollod, and roIIod/comprossod lo
romovo voids. Tlon llo lop Iayor of poIymor is appIiod
ovor llo roinforcing fibors lo provido a smooll, mono-
Iillic Iinor.
If puIlrudod or proimprognalod carbon is boing
uliIizod, llon llo appIicalion procoss slaII bo as foIIovs:
appIy adlosivo Iayor of poIymor
pross llo carbon inlo llo adlosivo poIymor
appIy llo lop coal lo llo slrucluraI Iinor lo pro-
vido a smooll, monoIillic surfaco
5 XAMIhA1I0h
5.1 1est 5ampIe ketrievaI
SampIos may bo laIon in accordanco vill llo foIIov-
ing for oacl CIII balcl inslaIIod:
SampIos slaII bo laIon on coupon spocimons idon-
licaI lo maloriaI appIiod onlo llo losl pipo (simiIarIy
curod).
Numbor of sampIos slaII bo sufficionlIy Iargo lo
provido slalislicaIIy adoqualo numbor of spocimons for
oacl of llo losl procoduros roquirod in maloriaI losling
(para. 5.2).
SampIos slaII bo marIod lo provido lracoabiIily.
5.2 MateriaI 1esting
Tlo losl sampIos oblainod in accordanco vill llo
para. 5.1 roquiromonls for losl sampIo rolriovaI slouId
bo loslod lo confirm llo foIIoving dosign basis maloriaI
proporly vaIuos:
limo-lomporaluro-corroclod fIoxuraI moduIus of
oIaslicily for CIII (
from Mandalory Appondix I)

limo-lomporaluro-corroclod uIlimalo lonsiIo
slrongll of CIII (
from Mandalory Appondix I)

llo coofficionl of llormaI oxpansion usod in llo
anaIysis roquirod by Mandalory Appondix I
5.3 CIPP-InstaIIed Ceemetry veriIicatien
Tlo minimum inslaIIod CIII vaII llicInoss slaII
bo vorifiod lo mool llo dosign roquiromonls using uIlra-
sonic or ollor oxaminalions.
Ixaminalion slaII bo in accordanco vill approvod
procoduros by quaIifiod porsonnoI.
A sol of four moasuromonls, oquaIIy spacod
around llo circumforonco of llo CIII, slouId bo laIon
al oacl ond and al ono inlormodialo poinl.
AddilionaI sols of moasuromonls slouId bo laIon
in aroas of significanl losl pipo dogradalion.
5.4 ecumentatien eI CIPP As-InstaIIed Cenditien
A visuaI oxaminalion slaII bo porformod.
Voids, surfaco fIavs, and aroas of impropor curing
slaII bo ovaIualod.
178
AII inspoclion/oxaminalion and corroclivo aclion
slaII bo in accordanco vill Mandalory Appondix II.
5.5 Menitering PIans
A pIan for moniloring llo corrosion ralo of a par-
liaIIy dolorioralod losl pipo slaII bo proparod.
No moniloring pIan is roquirod for a fuIIy dolorio-
ralod losl pipo, sinco llo CIII is sizod lo provido fuII
slrucluraI inlogrily.
A pIan for moniloring CIII for dogradalion duo
lo onvironmonl aI condil ions, orosion, or llormaI
oxpansion/conlraclion slouId bo proparod.
6 151IhC
A syslom prossuro losl slaII bo porformod on llo CIII
as spocifiod in paras. 6.1 and 6.2.
6.1 IseIabIe Pipe
6.1.1 Pressure ecay 1est. Tlo syslom inlogrily losl
for buriod compononls llal aro isoIabIo by vaIvos or
ollor moans slouId consisl of prossuro docay ovor limo
llal dolorminos llo IoaIago ralo.
6.1.2 FIuid veIume Makeup 1est. AIlornalivoIy, llo
syslom inlogrily losl may consisl of a fIuid voIumo
maIoup lo mainlain a sol prossuro ovor limo llal dolor-
minos llo IoaIago ralo.
6.1.3 Acceptance Criteria. Tlo accoplabIo ralo of
prossuro Ioss or voIumo maIoup slouId bo oslabIislod
ovor a minimum of 1 lr. Iaclors llal may infIuonco llo
accoplabIo ralo of prossuro Ioss or voIumo maIoup aro
voIumo of llo syslom prossuro losl
IoaI ligllnoss roquiromonls for llo buriod
compononls
6.2 heniseIabIe Pipe
6.2.1 FIew Impairment 1est. Tlo syslom inlogrily
losl for nonisoIabIo buriod compononls slouId consisl
of a losl lo confirm llal fIov during oporalion is nol
impairod.
6.2.2 Change in FIew1est. AIlornalivoIy, llo syslom
inlogrily losl may dolormino llo clango in fIov bolvoon
llo onds of llo buriod compononls.
6.2.3 Acceptance Criteria. Tlo accoplabIo fIov or
clango in fIov slouId bo oslabIislod.
7 kFkhC5
7.1 keIerenced Cedes and 5tandards
AII RI 579 (Ialosl odilion), Iilnoss-for-Sorvico
Slrool, NW, Waslinglon, DC 20005-4070
ASMI B31G-1991, ManuaI for Dolormining llo
Romaining Slrongll of Corrodod IipoIinos: A

SuppIomonl lo ASMI B31 Codo for Irossuro Iiping
ASMI IIS-1-2007, Iilnoss-for-Sorvico
Box 2300, IairfioId, N} 07007-2300
Iroporlios of IIaslics
ASTM D 696-2003, Slandard Tosl Mollod for Coofficionl
of Iinoar TlormaI Ixpansion of IIaslics Bolvoon
ASTM D 790-2003, Slandard Tosl Mollod for IIoxuraI
Iroporlios of Unroinforcod and Roinforcod IIaslics
and InsuIaling MaloriaIs
ASTM D 903-1998, Slandard Tosl Mollod for IooI or
Slripping Slrongll of Adlosivo Bonds
ASTM D 2105-1997, Slandard Tosl Mollod for
IongiludinaI TonsiIo Iroporlios of IiborgIass (GIass-
Iibor-Roinforcod Tlormosolling-Rosin) Iipo and Tubo
ASTM D 2583-1995, Tosl Mollod for Indonl alion
Hardnoss of Rigid IIaslics by Moans of BarcoI
Improssor
ASTM D 2990-2001, Slandard Tosl Mollod for TonsiIo,
Comprossivo, and IIoxuraI Croop and Croop-Rupluro
of IIaslics
ASTM D 4258 (Ialosl odilion), Slandard Iraclico for
Surfaco CIoaning Concrolo for Coaling
ASTM D 5162 (Ialosl odilion), Slandard Iraclico for
Disconlinuily (HoIiday) Tosling of Nonconduclivo
Iroloclivo Coaling on MolaIIic Subslralos
ASTM G 14-2004, Slandard Tosl Mollod for Impacl
Rosislanco of IipoIino Coalings (IaIIing Woigll Tosl)
BS IN 59-1977, Moasuromonl of lardnoss by moans of
a BarcoI improssor
BS IN 1465-1995, Dolorminalion of lonsiIo Iap sloar
slrongll of rigid lo rigid bondod assombIios
ISO 178-2001, IIaslics Dolorminalion of fIoxuraI
proporlios
ISO 527-1993, IIaslics Dolorminalion of lonsiIo
proporlios
ISO 868-2003, IIaslics and obonilo Dolorminalion of
indonlalion lardnoss by moans of a duromolor (Sloro
lardnoss)
179
NACI RI 0188-1988, Disconlinuily (HoIiday) Tosling of
Iroloclivo Coaling
IubIislor: NalionaI Associalion of Corrosion Inginoors
(NACI InlornalionaI), 1440 Soull CrooI Drivo,
Houslon, TX 77084-4906
SSIC-SI10 (Ialosl odilion), Noar-Wlilo MolaI BIasl
CIoaning
IubIislor: Tlo Socioly for Iroloclivo Coalings (SSIC),
40 24ll Slrool, Iillsburgl, IA 15222-4656
7.2 keIated Cedes and 5tandards
Tlo foIIoving aro roIalod codos and slandards. UnIoss
ollorviso spocifiod, llo mosl roconl slandard (Ialosl odi-
lion) avaiIabIo slaII bo usod.
Division 1, Subsoclion ND (ND-3611.2), Ii ping
Dosign/GonoraI Roquiromonls/AccoplabiIily/Slross
Iimils
Division 1, Subsoclion ND |ND-3672.6(a)], Iiping
Dosign/GonoraI Roquiromonls/Ixpansion and
IIoxibiIily/Slrossos/Slross Rango
ASMI BoiIor and Irossuro VossoI Codo, Codo Caso
N-589-1-2002, CIass 3 NonmolaIIic Curod-in-IIaco
Iiping, Soclion XI, Division 1
ASMI B31.1, Iovor Iiping
ASMI B31.4, IipoIino Transporlalion Sysloms for Iiquid
Hydrocarbons and Ollor Iiquids
ASMI B31.5, Rofrigoralion Iiping
ASMI B31.8, Gas Transmission and Dislribulion Iiping
Sysloms
ASMI B31.9, BuiIding Sorvicos
ASMI B31.11, SIurry Transporlalion Iiping Sysloms
ASTM D 1763, Slandard Spocificalion for Ipoxy Rosins
ASTM D 2837, Slandard Tosl Mollod for Oblaining
Hydroslalic Dosign Basis for TlormopIaslic Iipo
MaloriaIs
ASTM D 2992, Iraclico for Oblaining Hydroslalic or
Irossuro Dosign Basis for GIass Iibor Roinforcod
Tlormosolling Rosin Iipo and Iillings
ASTM D 4787, Slandard Iracl ico for Conlinuily
Vorificalion of Iiquid or Slool Iining AppIiod lo
Concrolo Subslralos
ASTM I 412, Slandard TorminoIogy RoIaling lo IIaslic
Iiping Sysloms
ASTM G 8, Slandard Tosl Mollod for Callodic
Disbonding of IipoIino Coalings

AWWA C-150/A21.51, Slandard for TlicInoss Dosign
of DucliIo Iron Iipo
AWWA C-151/A21.51, Slandard for DucliIo Iron Iipo,
ConlrifugaIIy Casl, for Walor or Ollor Iiquids
AWWA C-200, Slandard for SlooI Walor Iipo 6 in. and
Iargor
AWWA C-300, Slandard for Roinforcod Concrolo Iros-
suro Iipo, SlooI-CyIindor Typo, for Walor and Ollor
Iiquids
AWWA C-301, Slandard for Iro-slrossod Concrolo
Irossuro Iipo, SlooI-CyIindor Typo, for Walor and
Ollor Iiquids
AWWA C-302, Slandard for Roinforcod Concrolo
Irossuro Iipo, Non-cyIindor Typo
AWWA C-303, Slandard for Concrolo Irossuro Iipo,
Bar-Wrappod SlooI-CyIindor Typo
AWWA C-900, Slandard for IoIyvinyI ClIorido (IVC)
Irossuro Iipo, 4 in. Tlrougl 12 in., for Walor
Dislribulion
AWWA C-905, Slandard for IoIyvinyI ClIorido (IVC)
Walor Transmission Iipo, NominaI Diamolor 14 in.
llrougl 36 in.
AWWA C-906, Slandard for IoIyollyIono (II) Irossuro
Iipo and Iillings, 4 in. llrougl 63 in., for Walor
Dislribulion
AWWA C-950, Slandard for IiborgIass Irossuro Iipo
AWWA M-11, SlooI Iipo A Guido for Dosign and
InslaIIalion
AWWA M-23, IVC Iipo Dosign and InslaIIalion
AWWA M-45, IiborgIass Iipo Dosign
180
6666 Wosl Quincy Avonuo, Donvor, CO 80235
SSIC-SI5 (Ialosl odilion), Wlilo MolaI BIasl CIoaning
SSIC-SI6, CommorciaI BIasl CIoaning
SSIC-SI7, Brusl-Off BIasl CIoaning
SSIC-SI8, IicIIing
IubIislor: Socioly for Iroloclivo Coalings (SSIC),
40 24ll Slrool, Iillsburgl, IA 15222-4656
7.3 keIated 1echnicaI PubIicatiens
G. A. AnlaIi, A Roviov of Mollods for llo
AnaIysis of Buriod Irossuro Iiping, WoIding Rosoarcl
CounciI BuIIolin 425, Nov YorI, Soplombor 1997
R. H. WaIIor and C. W. RovIoy, SlrucluraI Iining
Sysloms in llo Sorvico Walor Invironmonl, IIRI 12ll
AnnuaI Sorvico Walor Sysloms RoIiabiIily Improvomonl
Sominar, BiIoxi, Mississippi, }uIy 1999
I. C. GoodIing, Buriod Iiping An AnaIysis
Irocoduro Updalo, ASMI IVI, 1983
A. I. Mosor, Buriod Iipo Dosign, McGrav
HiII, 1990
R. K. WalIins and A. I. Mosor, SoiI and Surfaco
Ioads on Buriod Iipos IncIuding Minimum Covor
Roquiromonls, ASMI IVI, VoIumo 360, 1998
Dosign of Buriod SlooI Iipo, Amorican IifoIino
AIIianco, ASCI, Roslon, VA, Ialosl odilion
D. I. Adams, I. A. CarIsson, and R. B. Iipos,
IxporimonlaI Claraclorizal ion of Advancod
Composilo MaloriaIs, CRC Iross, Tlird Idilion, 2003

esign Censideratiens Ier uried Pipe
I-1 wALL 1hICkh55 0F CIPP
Tlo roquirod CIII dosign vaII llicInoss,
, for
a parliaIIy dolorioralod losl pipo (dosign appIicalion
Calogory B) slaII bo al Ioasl llo groalor of llo llicInoss
dolorminod by oqs. (I-1) and (I-3). Tlis minimum llicI-
noss slaII bo incroasod lo provido for aII appIicabIo man-
ufacluring-spocific inslaIIalion conslruclabiIily
loIorancos and slaII bo usod in llo dosign anaIysis.
1
Tlo
for a fuIIy dolorioralod losl pipo slaII bo

al Ioasl llo groalor of llo llicInoss dolorminod by
oqs. (I-1) and (I-2). Tlis minimum llicInoss slaII bo
incroasod lo provido for aII appIicabIo manufacluring-
spocific inslaIIalion conslruclabiIily loIorancos, slaII bo
roforrod lo as
, and slaII bo usod in llo anaIysis

roquirod by anaIysis oqualions boIov.
1
I-2 5ICh bA1I0h5
I-2.1 InternaI Pressure
Iqual ion (I-1) slaII bo usod lo dolormino llo
roquirod duo lo inlornaI prossuro on CIII conlainod in

a parliaIIy or fuIIy dolorioralod losl pipo.
+ 1
(I-1)
vloro
oulsido diamolor of CIII (insido diamolor of

losl pipo), mm (in.)
dosign safoly faclor (lypicaIIy 2)
inlornaI dosign prossuro, MIa (psig)

slrongll of CIII, MIa (psi)
roquirod CIII dosign vaII llicInoss, mm (in.)

I-2.2 xternaI Pressures]FuIIy eterierated Pipes
roquirod duo lo appIicabIo oxlornaI prossuros on CIII

conlainod in a fuIIy dolorioralod losl pipo.
0.721
/ )
2

1/3
(I-2)
1
AIllougl llo parliaIIy dolorioralod losl pipo assumplion couId
rosuIl in a llinnor vaII llicInoss llan a fuIIy dolorioralod losl
pipo, il viII roquiro fuluro moniloring of llo losl pipo vloroas
llo fuIIy dolorioralod pipo viII nol.
181
vloro
coofficionl of oIaslic supporl
1/(1+4o
(m)
) 1/(1+4o
(fl)
)
ovaIily roduclion faclor

100
/ 1 +
100
2
3
limo-lomporaluro-corroclod fIoxuraI moduIus

of oIaslicily for CIII, MIa (psi)
moduIus of soiI roaclion, MIa (psi)

loigll of soiI abovo lop of losl pipo, m (fl)
loigll of groundvalor abovo lop of losl pipo,

m (fl)
Dosign Iaclor (lypicaIIy 2)

ovaIily () of losl pipo
100
avorago moasurod dia.
lolaI oxlornaI prossuro on CIII, MIa (psi)
valor buoyancy faclor (0.67 min.)

/)]
I-2.3 xternaI Pressures]PartiaIIy eterierated Pipes
roquirod duo lo appIicabIo oxlornaI prossuros on CIII

conlainod in a parliaIIy dolorioralod losl pipo.
2
)
1/3
+ 1
(I-3)
vloro
bucIIing onlancomonl faclor of llo soiI and
losl pipo adjaconl lo CIII. A vaIuo of 7.0 may
bo usod.
groundvalor lydrauIic Ioad, MIa (psi)

Ioissons ralio 0.30, or Ioissons ralio may
bo dolorminod using llo losl mollod of
ASTM D 2105
I-3 APPLI L0A5 5ICh
To vaIidalo CIII dosign, llo anaIysis slaII considor
llo offocls duo lo appIicabIo suslainod and occasionaI
Ioads spocifiod in llo ovnors roquiromonls.

I-3.1 5ustained and 0ccasienaI Leads
Slrossos duo lo suslainod and occasionaI Ioads slaII
mool llo roquiromonls of oq. (I-4).
+ 0.75
4
(I-4)
vloro
cross-soclionaI aroa of CIII, mm
2
(in.
2
)
oulsido diamolor of CIII, mm (in.)

slross inlonsificalion faclor (SII). Tlo SII for
sprayod form CIII in a slraigll or curvod
losl pipo slaII bo laIon as unily, llus 0.75
oquaIs 1
occasionaI Ioad faclor 1.2, if occasionaI
Ioads aro incIudod in oq. (I-4), ollorviso,
1
rosuIlanl momonl Ioading on cross soclion

duo lo voigll and ollor appIicabIo suslainod
Ioads, Nmm (in.-Ib). If llo CIII is conlinu-
ousIy supporlod by llo oxisling soiI syslom
or llo parliaIIy dolorioralod losl pipo, llo
lorm may bo nogIoclod.

duo lo appIicabIo occasionaI Ioads, sucl as
llrusls from roIiof and safoly vaIvo Ioads,
from prossuro and fIov lransionls, and sois-
mic inorlia, Nm (in.-Ib). Ior soismic inorlia,
llo caIcuIalion may uso onIy ono-laIf of llo
rango. Tlo offocls of soismic dispIacomonls
may bo oxcIudod from oq. (I-4) if lloy aro
incIudod in oq. (I-5).
maximum oporaling prossuro, MIa (psig)
moan radius of CIII, mm (in.)

182
axiaI Ioading on cross soclion duo lo soismic
dispIacomonls or ollor appIicabIo occasionaI
Ioads, N (Ib)

slrongll of CIII, MIa (psi)
nominaI CIII vaII llicInoss, mm (in.)

soclion moduIus of CIII, mm
3
(in.
3
)

I-3.2 1hermaI xpansien Leads

Slrossos duo lo llormaI oxpansion Ioads slaII mool
llo roquiromonls of oq. (I-5).
2
(I-5)
vloro

duo lo llormaI oxpansion, N mm (in.-Ib).
AIso, incIudos momonl offocls of soismic dis-
pIacomonls if lloy voro omillod fromoq. (I-4).
axiaI Ioading on cross soclion duo lo soismic
dispIacomonls, if incIudod, and llormaI
oxpansion, N (Ib)
I-3.3 eterminatien eI kesuItant Mement
Ior oqs. (I-4) and (I-5), llo rosuIlanl momonls for
slraigll and curvod piping mombors slaII bo caIcuIalod
as foIIovs:
2
+
2
+
2
)
vloro
A, B, or C, as dofinod in oqs. (I-4) and (I-5)

Inspectien]xaminatien and Cerrective Actien
kequirements Ier CIPP
II-1 ChkAL
AII roquirod corroclivo aclions lo llo CIII duo lo
voids, surfaco fIavs, and aroas of impropor curing slaII
bo in accordanco vill llis Appondix.
II-2 P0LMk MIX1bk
II-2.1 keaI-time Mixture CentreI
Mixluro conlroI may bo confirmod by coIor of llo
poIymor, por llo manufaclurors rocommondalions.
II-2.2 kesuItant Mixture CentreI
CoIor clips from llo manufacluror may bo usod lo
comparo poIymor lo llo propor mixluro of poIymor.
II-3 P0LMk 1hICkh55 5AMPLIhC
II-3.1 humber eI Layers
Tlo poIymor-fibor malrix llicInoss may bo moasurod
basod on Iayor llicInoss from llo manufacluror limos
llo numbor of Iayors. Tlis llicInoss may bo comparod lo
llo minimum dosign caIcuIalions for roquirod llicInoss.
II-3.2 h Measurement
Tlo poIymor-fibor malrix llicInoss may bo moasurod
vill UT or ollor NDI inslrumonls.
II-4 P0LMk hAkh55
II-4.1 hardness Measurement
Tlo lardnoss of llo curod poIymor may bo moasurod
for quaIily conlroI of llo inslaIIod mix ralio.
BarcoI lardnoss por ASTM D 2583 or BS IN 59
Sloro lardnoss por ASTM D 2240 or ISO 868
II-4.2 5ampIe Peints
Hardnoss sampIo poinls may bo dolorminod al ran-
dom approximaloIy ovory llroo fool on inslaIIod Iongll
and al approximaloIy four circumforonliaI poinls. Hard-
noss sampIo poinls slouId aIso bo laIon vlorovor llo
inslaIIod visuaI coIor of llo poIymor IooIs unovon (indi-
calos possibIo poor mixing of poIymor rosin and curing
agonl).
183
II-4.3 Curing CataIyst
Tlo curing procoss may bo onlancod by llo addilion
of llo curing calaIysl (o.g., loal, valor, UV radialion).
II-5 P0LMk C0vkAC
II-5.1 visuaI Inspectien
Tlo poIymor covorago may bo visuaIIy inspoclod lo
idonlify pin loIos and imporfoclions.
II-5.2 heIiday 1est
A loIiday losl as spocifiod by llo manufacluror
(vloso roquiromonls aro lypicaIIy basod on ASTM
D 5162 or NACI RI 0188) may bo usod lo idonlify pin
loIos and llin spols in llo poIymor covorago. Tlis losl is
vory offoclivo for poIymors vill gIass roinforcing fibors.
Wlon carbon roinforcing fibors aro uliIizod, lloy nood lo
bo insuIalod from llo molaIIic subslralo vill a poIymor
primor, poIymor-saluralod gIass cIoll, or boll for llo
loIiday losl lo bo offoclivo.
II-6 5bkFAC FC1 C0kkC1Iv AC1I0h5
II-6.1 5ubstrate Preparatien
Grind avay llo poIymor around llo surfaco dofocl lo
croalo adlosivo bonding silos.
II-6.2 PeIymer Mixing
Mix llo rosin and curing agonl of llo poIymor in
accordanco vill manufacluror s rocommondod
proporlions.
II-6.3 PeIymer AppIicatien
Spray or lrovoI llo poIymor ovor llo surfaco dofocl.
II-6.4 PeIymer Inspectien
Inspoclion of llo poIymor syslom, appIiod lo llo sur-
faco dofocl in accordanco vill llo CIII poIymor manu-
(08)

faclurors rocommondalions, slaII bo llo dolormining
faclor in judging curo compIolion.
II-6.5 xcess PeIymer
Grind avay, as roquirod, llo oxcoss poIymor so llal
llo corroclivo aclion foIIovs llo conlour of llo oxisling
CIII. Nolo llis oxcoss poIymor onIy affocls llo fIov
surfaco of llo pipo, nol llo slrucluraI aspocls of llo CIII.
184
II-7 C0kkC1Iv AC1I0h F0k AkA5 0F
Ih5bFFICIh1 CbkIhC
Aroas of insufficionl curing slaII bo compIoloIy cor-
roclod by slops idonlifiod in para. II-6 abovo. Inspoclion
in accordanco vill llo CIII poIymor manufaclurors
rocommondalions slaII bo llo dolormining faclor in
judging curo compIolion.
(08)

III-1 CL055Ak 0F 1kM5
llo buriod piping modificalion
mollod vill a llormosol poIymor inlo a losl pipo.
llo clanging of maloriaI proporlios of a llormo-
sol poIymoric syslom by llo appIicalion of loal, valor,
radialion, or ollor moans inlo a moro slabIo and usabIo
condilion.
lloso aro usuaIIy a lvo-compononl llormosol
poIymoric syslom primariIy composod of opiclIoraly-
drin and BisplonoI A combinod vill an amino-basod
curing agonl.
a losl pipo llal is nol roIiod
upon lo supporl soiI, surclargo, or groundvalor Ioads.
llo oId oxisling pipo lo bo modifiod.
a losl pipo llal is roIiod
upon lo supporl soiI and surclargo Ioads llrougloul
ils dosign Iifo.
a pIaslic mal oriaI llal can bo llormosol
(lvo-parl poIymor) or llormopIaslic (ono-parl poIymor)
in naluro.
a roIalivoIy inorl maloriaI addod lo a poIy-
mor lo modify ils slrongll, pormanonco, or vorIing
proporlios.
a roIalivoIy llin slrip of poIymor and
carbon aIroady curod and somovlal maIIoabIo lo form-
ing lo llo appIicalion goomolry.
ligl slrongll fibors imboddod in llo poIy-
mor, rosuIling in moclanicaI proporlios suporior lo lloso
of llo baso poIymor villoul llo fibors.
185
Ioading on a buriod losl pipo producod by
ground lransporlalion lraffic, o.g., lrucI or raiIvay.
lloso aro pIaslics llal cannol bo ro-
soflonod foIIoving poIymorizalion (incIudos BaIoIilo,
opoxy, poIyurollano, poIyoslors, vinyI oslors, and
painls).
III-2 CL055Ak 0F ACk0hM5
(ASMI).
(ASTM InlornalionaI)
Amorican Walor WorIs Associalion
Brilisl Slandards
curod-in-pIaco pipo
dimonsionaI numbor
insido diamolor
InlornalionaI Organizalion for Slandardizalion
maloriaI safoly dala slool
NalionaI Associalion of Corrosion Inginooring
nondoslruclivo oxaminalion
NominaI Iipo Sizo
OccupalionaI Safoly and HoaIll Adminislralion
SlooI Slrucluros Iainling CounciI Slandards
uIlra vioIol (radialion)
(08)
(08)

PAk1 5
XAMIhA1I0h Ah 151IhC
ArticIe 5.1
Pressure and 1ightness 1esting eI Piping and quipment
1 5CkIP1I0h
Tlis ArlicIo providos gonoraI good praclico for
dolormining llo lypo of losl, llo losl prossuro, and llo
procoduro for prossuro and ligllnoss losling of prossuro
oquipmonl, incIuding lubuIar loal oxclangors, prossuro
vossoIs, and piping sysloms.
GonoraI informalion rogarding llo various lypos
of losls lo clooso from is providod, incIuding appIica-
lion, bonofils, and Iimilalions.
Rofor lo individuaI ropair arlicIos of ICC-2 for any
prossuro or IoaI losling roquiromonls or rocommonda-
lions llal slouId bo foIIovod.
2 LIMI1A1I0h5
Tlis ArlicIo slaII bo usod for fioId prossuro or
ligllnoss losling of oxisling oquipmonl and piping using
oillor of llo lvo fIuid modiums, Iiquid or gas.
Tlis ArlicIo slaII nol bo usod for vacuum losling
of oquipmonl or piping.
Tlis ArlicIo doos nol addross uso of dovicos or
mollods lo isoIalo a syslom or a compononl lo porform
prossuro or ligllnoss losling. Tlo usor is caulionod lo
onsuro llal uso of any dovico is dono in accordanco vill
llo roquiromonls of ils manufacluror, and llo isoIalion
of any syslomfor prossuro or ligllnoss losling is vorifiod.
Tlis ArlicIo addrossos pnoumalic losling. Inou-
malic losling is polonliaIIy lazardous, mucl moro llan
lydroslalic losling duo lo llo liglor IovoIs of polonliaI
onorgy in llo prossurizod syslom, lloroforo, aII roason-
abIo aIlornalivos slaII bo considorod boforo llis oplion
is soIoclod.
3 5ICh
3.1 eIinitiens
llo finaI voId connocling piping sysloms
or compononls llal lavo boon succossfuIIy prossuro
186
loslod in accordanco vill llo appIicabIo codo of
conslruclion.
a prossuro or ligllnoss losl vloro Iiquid,
lypicaIIy valor, is llo losl modium.
a losl using llo procoss modium of
llo prossuro oquipmonl porformod al slarl-up of llo
oquipmonl.
a prossuro or ligllnoss losl vloro a gas,
gonoraIIy nilrogon or air, is llo losl modium.
a losl porformod lo onsuro llo gross inlog-
rily of llo prossuro compononl on nov prossuro oquip-
monl, or on proviousIy manufaclurod prossuro and
piping oquipmonl llal las boon or is in sorvico and
llal las undorgono an aIloralion or ropair lo a prossuro
boundary(s) lo onsuro llo gross inlogrily of llo prossuro
compononl lo llo originaI codo of conslruclion. A pros-
suro losl may bo porformod vill Iiquid (lydroslalic
losl), vill gas (pnoumalic losl), or a combinalion of boll
(lydro-pnoumalic losl).
a losl llal is porformod lo onsuro ovoraII
IoaI ligllnoss of llo syslom or ils connoclions boforo
llo procoss modium is inlroducod.
3.2 keasens Ier Pressure and 1ightness 1esting
Tlo primary purposo of porforming a prossuro
losl is lo vorify llo inlogrily of a prossuro syslom. Tlis
is ospociaIIy lruo vlon voIdod ropairs or aIloralions
lavo boon porformod on llo prossuro boundary. Irossuro
and ligllnoss losling aro nol subslilulos for proof losling
a dosign.
Irossuro or ligllnoss losls can bo usod lo clocI
for prossuro syslom IoaIago, ospociaIIy in fIangod joinls.
Tigllnoss losls may bo porformod in conjunclion vill
llo prossuro losl.
Hydroslalic prossuro losling can provido somo
moclanicaI slross roIioving. Tlis is accompIislod vlon

IocaI rogions of ligl slross, sucl as al slross conconlra-
lions and cracI-IiIo imporfoclions, undorgo IocaI yioId-
ing during llo prossuro losl. RoIoaso of prossuro llon
producos comprossivo rosiduaI slross in lloso rogions,
sucl llal vlon prossuro is roappIiod, llo oporaling
slross is Ioss llan vouId lavo occurrod ollorviso. Tlis
can loIp miligalo llo risI of brillIo fracluro vlon il
is a considoralion. Subsoquonl oporalion, ospociaIIy al
oIovalod lomporaluros, can roduco or oIiminalo any bon-
ofil lovard slross roIiof or brillIo fracluro conlroI. Hydro-
slalic prossuro losling doos nol oIiminalo llo nood for
poslvoId loal lroalmonl, vlollor roquirod by llo appIi-
cabIo codo of conslruclion or by llo usors roquiromonls.
Tigllnoss losling may bo considorod vlon slruc-
luraI inlogrily doos nol nood lo bo vorifiod bul vlon
IoaI ligllnoss musl bo vorifiod prior lo slarl-up.
In-sorvico IoaI losling can bo considorod vlon
slrucluraI inlogrily doos nol nood lo bo vorifiod and llo
consoquoncos of a IoaI during slarl-up aro accoplabIo,
or vlon pormillod by llo appIicabIo codo of conslruc-
lion or posl-conslruclion codo.
3.3 1est 1ype 5eIectien
Tlo roquiromonl for prossuro losling can bo found in
codo. Wlon no losl is spocificaIIy roforoncod, Iig. 1 slaII
bo usod lo dolormino llo lypo of losl lo bo porformod.
3.4 Pressure 1est CeneraI
A prossuro losl of oquipmonl or a piping syslom
slouId bo considorod if an aIloralion or ropair las boon
porformod, if llo oquipmonl las boon roralod, or il noods
lo bo rocorlifiod lo dolormino inlogrily.
A prossuro losl may nol bo roquirod for roraling
oquipmonl using a liglor aIIovabIo slross sinco llo orig-
inaI prossuro losl couId bo liglor llan llo losl prossuro
roquirod for roraling.
Irossuro losling |or aIlornalivoIy, ligllnoss losling,
soo para. 6.3(a)] slouId bo considorod during roulino
inspoclions and aflor cIoaning oporalions vlon llo
inlogrily of lubo-lo-luboslool joinls is in quoslion. IoI-
Ioving llo compIolion of llo prossuro losl, llo lubos
slouId bo inspocl od for bucIIing llal may lavo
occurrod.
3.4.1 xcIusiens Frem hydrestatic 1est. Irossuro
losling slouId bo porformod lydroslalicaIIy unIoss ono
of llo condilions spocifiod in llo foIIoving appIy:
Tlo oquipmonl, piping, and/or supporls, incIud-
ing foundalions, cannol adoqualoIy supporl llo Iiquid
voigll.
Tlo oquipmonl or piping cannol bo driod and
lracos of llo losl Iiquid may rosuIl in conlaminalion of
llo syslom or ils conlonls aflor rolurning lo sorvico.
Tlo oquipmonl or piping conlains inlornaI Iinings
llal couId bo damagod by llo losl modium.
187
3.4.2 Pneumatic 1est Cenditiens. If a lydroslalic
losl cannol bo porformod por para. 3.4.1, llon a pnou-
malic prossuro losl slouId bo considorod.
If a pnoumalic prossuro losl vouId prosonl unac-
coplabIo lazards sucl as risI of brillIo fracluro al llo
molaI losl lomporaluro, llon a subslilulion for prossuro
losling slouId bo dovoIopod.
Soo aIso para. 6.2(d) for informalion rogarding llo
nood for risI anaIysis.
3.4.3 hendestructive xaminatien Censideratiens.
Nondoslruclivo oxaminalion may bo considorod in Iiou
of prossuro losling lo vorify ropairs or aIloralions in
somo inslancos. Tlis may roquiro llo uso of ligllnoss
losling as voII.
3.5 ecumentatien
A prossuro losl rocord form slouId bo proparod prior
lo llo prossuro losl and compIolod upon accoplanco of
llo losl by llo ovnor or llo ovnors dosignalod ropro-
sonlal ivo. A sampIo rocord form is providod in
4 FAkICA1I0h
Willin llo conloxl of llis ArlicIo, llis soclion is nol
appIicabIo.
5 XAMIhA1I0h
Willin llo conloxl of llis ArlicIo, visuaI oxaminalion
slaII bo porformod during llo prossuro, ligllnoss, or
in-sorvico IoaI losl lo dolormino if any IoaIago is
occurring during llo losl. Wlon visuaI oxaminalion is
nol possibIo, sucl as for undorground piping, monilor-
ing of syslom prossuro for prossuro drop during ligll-
noss or in-sorvico IoaI losl may bo subslilulod vlon
approvod by llo ovnor. Soo aIso paras. 6.1(l)(8) and
6.2.1.3(c) rogarding safoly praclicos.
6 151IhC
6.1 hydrestatic Pressure 1est eI Pressure vesseIs er
Piping 5ystems
Tlo fabricalion and in-sorvico inspoclion rocords
aIong vill any nocossary oporalionaI rocords slouId bo
roviovod prior lo losling lo dolormino if llo prossuro
compononl/syslom las oxporioncod a crodibIo damago
moclanism. Considoralion slouId bo givon lo lov oacl
moclanism couId manifosl ilsoIf during a prossuro losl.
Soclion 7 providos roforoncos llal provido considora-
lions for damago moclanisms.
Tlo inspoclion rocords slouId bo roviovod for
llinning boyond llo spocifiod Iimil. If llinning las
occurrod boyond llo spocifiod corrosion aIIovanco, an
onginooring ovaIualion slaII bo porformod using curronl
inspoclion dala.

Fig. 1 1est 1ype 5eIectien

188

Tlo maloriaI may lavo boon subjoclod lo dam-
ago duo lo lomporaluro or procoss oxposuro. If ovidonco
of damago is found by inspoclion, an onginooring ovaIu-
alion slaII bo porformod using curronl inspoclion dala.
Tlo compononl/syslom may lavo boon dam-
agod by moclanicaI moans sucl as ligl vibralion. Con-
sidoralion slouId bo givon lo anaIyzing llo syslom for
aroas vloro damago couId occur and llon inspocling
lloso aroas prior lo losling lo IooI for ovidonco of
damago.
In ordor lo roduco llo risI of brillIo fracluro during
llo losl, llo lomporaluro of llo molaI during llo prossuro
losl of prossuro vossoIs slouId bo mainlainod al a mini-
mum of 17C (30I) abovo llo minimum dosign molaI
lomporaluro (MDMT) (as slovn on llo Manufaclurors
Dala Roporl).
If llo MDMT is unInovn, llo minimum aIIov-
abIo lomporaluro (MAT) of llo compononl or syslom
slouId bo dolorminod using a filnoss-for-sorvico
ovaIualion.
If a vossoI mado of Iov aIIoy slooI las boon
subjoclod lo llormaI lroalmonl or sorvico lomporaluros
ovor 370C (700I), an upvard slifl in llo ducliIo-lo-
brillIo lransilion lomporaluro may lavo occurrod. Tlis
Ioss of louglnoss may nol bo roadiIy apparonl during
oporalion, lovovor, llo vossoI may bo suscoplibIo lo
brillIo fracluro. Tloroforo, llo lomporaluro usod for llo
prossuro losl may nood lo bo dolorminod by a filnoss-
for-sorvico ovaIualion.
Wlon prossuro losling piping sysloms, llo ambi-
onl lomporaluro slouIdbo groalor llan 2C(35I). Wlon
prossuro losling al coIdor lomporaluros, llo uso of an
anlifroozo soIulion slouId bo considorod as llo losl
modiumlo provonl froozing, lovovor, llo molaI lompor-
aluro slouId bo Iopl abovo llo ducliIo-brillIo lransilion
lomporaluro. AddilionaI guidanco rogarding prossuro
losling al coId lomporaluros may bo found in llo rofor-
oncos Iislod in soclion 7 of llis ArlicIo.
Tlo vossoI and ils supporls and llo foundalion
and/or llo piping syslom and ils supporls and supporl
slrucluros slouId bo ovaIualod lo dolormino if lloy viII
adoqualoIy supporl llo voigll of llo losl modium.
Irossuro gagos usod for rocording losl prossuros
slouId bo caIibralod and Iocalod al llo liglosl poinl on
llo vossoI or on llo piping syslom. Tlo gagos slouId
mool llo roquiromonls of ASMI ITC 19.2 or simiIar
gago porformanco slandard, andbo corroclodas roquirod
lo componsalo for llo slalic load prosonl in llo syslom.
Vonls slaII bo providod al llo ligl poinls of llo
vossoI and/or piping syslom lo purgo air fromllo loslod
compononl vliIo il is boing fiIIod.
Tlo vossoI or piping syslom slaII bo ovaIualod for
compononls llal viII nol villsland llo losl prossuro,
or viII ollorviso inlorforo vill a prossuro losl. IxampIos
of lloso compononls incIudo orifico pIalos, fIov nozzIos,
conlroI vaIvos, oxpansion joinls, olc.
189
An ovaIualion for llo nood of ovorprossuro roIiof
dovicos slaII bo porformod. Tlo sol prossuro of a pros-
suro roIiof dovico slouId bo no moro llan llo Iossor of:
llo losl prossuro pIus 345 IIa (50 psi), or
110 of llo losl prossuro
Considoralion slaII bo givon lo propor disposaI of
llo losl valor as il may conlain rosiduaI lracos of llo
syslom conlonls.
Irossuro losling slouId bo compIolod prior lo insu-
Ialing. WoIds or ollor joinls llal lavo proviousIy boon
prossuro loslod can bo insuIalod or ollorviso covorod
vlon agrood lo by llo ovnor-usor.
Irossuro losling slouId bo compIolod prior lo
painling voId joinls, unIoss llo voId joinls voro pro-
viousIy loslod. Documonlod losl rosuIls indicalo various
lypos of painl viII rolain prossuro during a prossuro
losl vlon covoring a llrougl-vaII pin-loIo. Wlon
considoring vlollor or nol voIds may bo painlod prior
lo prossuro losling, llo foIIoving slouId bo givon
considoralion:
llo painl syslom(s) boing usod and lloir abiIily
lo masI a polonliaI IoaI
llo probabiIily llal llo procoss fIuid(s) viII acl
as a soIvonl on llo painl syslom if a pin-loIo is prosonl,
llus incroasing llo polonliaI for a IoaI lo occur
llo offocl on noarby oquipmonl or porsonnoI if
a IoaI occurs
llo cosl of porforming ropairs in llo fioId if sucl
a faiIuro occurs
Il is nol roquirod for llo inspoclor approving llo
lydroslalic prossuro losl lo bo corlifiod por SNT-TC-1A
for IoaI Tosling or VisuaI Ixaminalion, lovovor, llo
inspoclor slouId lavo llo aullorily lo slop a prossuro
losl vlon doomod nocossary lo do so. Dodicalod Iinos of
communicalion slouIdbo in pIaco bolvoon llo inspoclor
laving ovorsigll aullorily and aII ollor porsonnoI por-
forming llo prossuro losl.
Tlo losl prossuro of a lydroslalic prossuro losl of
prossuro vossoIs or loal oxclangors slaII bo according
lo llo originaI codo of conslruclion, considoring aIso any
subsoquonl onginooring anaIysis as doomod nocossary.
Wlon llo roquiromonls of llo originaI codo of
conslruclion aro nol avaiIabIo, llo losl prossuro for a
lydroslalic prossuro losl for prossuro vossoIs or loal
oxclangors slaII bo llo Iossor of para. 6.1(n)(1) or
6.1(n)(2) boIov.
Iqualion (1)
1.3
(1)
vloro
maximum aIIovabIo vorIing prossuro
from llo Manufaclurors Dala Roporl, or
llo vaIuo lo vlicl llo vossoI is boing
roralod

losl prossuro lo bo usod, moasurod al llo

lop of llo vossoI in ils normaI oporaling
posilion
aIIovabIo slross al losl lomporaluro from

llo appIicabIo codo of conslruclion for llo
maloriaI of vlicl llo compononl undor
considoralion is conslruclod
aIIovabIo slross al dosign lomporaluro

from llo appIicabIo codo of conslruclion
for llo maloriaI of vlicl llo compononl
undor considoralion is conslruclod
llo ralio of aIIovabIo slrossos, llo Iovosl

vaIuo slaII bo usod in oq. (1) for aII malori-
aIs considorod 1.3 is llo losl faclor
A prossuro oquaI lo llal vlicl rosuIls in an
appIiod gonoraI primary mombrano lonsiIo slross oquaI
lo 90llo spocifiod minimumyioId slross al losl lompor-
aluro of carbon slooI maloriaI, or 100of auslonilic slooI
maloriaI. VaIuos for yioId slronglls for somo maloriaIs
aro providod in ASMI BIVC Soclion II, Iarl D.
Tlo losl prossuro for a lydroslalic prossuro losl
for piping sysloms slouId bo spocifiod by llo ovnor and
slaII bo according lo llo originaI codo of conslruclion.
Wlon llo roquiromonls of llo originaI codo of
conslruclion aro nol avaiIabIo, llo losl prossuro for a
lydroslalic prossuro losl for piping sysloms slouId bo
spocifiod by llo ovnor and slouId bo al Ioasl
1.5
(2)
vloro
inlornaI dosign prossuro of llo piping
syslom
losl prossuro lo bo usod, moasurod al llo

liglosl poinl of llo piping syslom in ils
normaI oporaling posilion


ralio of aIIovabIo slrossos, llo Iovosl vaIuo

slaII bo usod in oq. (2) for aII maloriaIs
considorod 1.5 is llo losl faclor.
Tlo rosuIling slross duo lo losl prossuro,
, slaII bo
Iimilod lo 100 of yioId slrongll,
.
If llo dosign prossuro of llo piping syslom cannol
bo vorifiod, llo vaIuo for in oq. (2) may bo llo Iossor
of para. 6.1(q)(1) or 6.1(q)(2), normaIizod lo llo liglosl
poinl of llo piping syslom.
190
Tlo vorIing prossuro al dosign lomporaluro for
fIangos in llo piping syslom from ASMI B16.5 or ollor
appIicabIo slandard.
Tlo maximumaIIovabIo prossuro caIcuIalod for
llo Iimiling compononl of llo piping syslom.
Tlo losl prossuro slouId nol oxcood llal vlicl
rosuIls in an appIiod gonoraI primary mombrano lonsiIo
slross groalor llan 100 llo spocifiod minimum yioId
slross al losl lomporaluro. YioId slronglls al ambionl
lomporaluro may bo found in ASMI B31.3 or ollor appIi-
cabIo codo of conslruclion. YioId slronglls al liglor lom-
poraluros may bo found in ASMI BIVC Soclion II,
Iarl D.
Irossuro losling of a piping syslom llrougl oquip-
monl is nol rocommondod. Iiping may bo loslod vill
a prossuro vossoI if il is impraclicaI lo isoIalo llo piping
from llo vossoI, llo losl prossuro of llo piping is oquaI
lo or Ioss llan llo losl prossuro of llo vossoI and llo
vossoI and ils supporls viII adoqualoIy supporl llo
voigll of llo losl Iiquid.
If llo losl prossuro of llo piping oxcoods llo losl pros-
suro of llo vossoI, llo vossoI losl prossuro can bo usod,
providod il is al Ioasl 77 of llo piping losl prossuro,
ollorviso llo piping slouId bo isoIalod from llo pros-
suro vossoI and prossuro loslod indopondonlIy.
Iiping sysloms llal oporalo al almosploric pros-
suro may bo IoaI loslod by fiIIing vill losl Iiquid onIy.
Tlo iloms spocifiod in paras. 6.1(l)(1) llrougl
6.1(l)(9) slouId bo considorod vlon dovoIoping lydro-
slalic prossuro losl procoduros for vossoIs or piping
sysloms.
AII oquipmonl and/or piping lo bo loslod
slouId bo vorifiod as boing cIoan of dirl, voId sIag,
conslruclion dobris, or ollor unaccoplabIo foroign
mallor.
Iloms idonl ifiod in para. 6. 1(g) slouId bo
romovod.
AII spring supporls in vapor sorvico Iinos slouId
bo proloclod vill adoqualo lravoI slops lo provonl ovor-
Ioading during llo prossuro losl.
Tomporary supporls slouId bo providod for
piping and/or piping supporls llal lavo nol boon
dosignod lo supporl llo voigll of llo losl Iiquid usod
for lydroslalic prossuro losl.
Tlo uso of saIl or bracIisl valor slouId bo
avoidod. Tosl valor slouId bo froo from sodimonl and
corrosivo subslancos.
Tlo losl valor slouId bo vorifiod lo bo froo of
microbos. If an unaccoplabIo IovoI of microbos is in llo
valor, il slouId bo disinfoclod.
Tosl valor usod for auslonilic slooI vossoIs or
piping sysloms, or for compononls cIad or ovorIaid vill
auslonilic slainIoss slooI, slouId bo condonsalo, domin-
oraIizod, or polabIo quaIily valor vill a vorifiod clIo-
rido conlonl of Ioss llan 50 ppm.

IoIIoving a loId-limo of a minimum of 10 min,
llo prossuro slouId bo roducod by 30 foIIovod by a
visuaI oxaminalion for ovidonco of IoaIs al Iocalions
sucl as fIangos, voId joinls, llroadod connoclions, and
any ropairod Iocalions.
Tosl Iiquid slouId bo drainod immodialoIy aflor
compIolion of llo lydroslalic losl. Caro slouId bo oxor-
cisod lo provido propor vonling lo provonl llo croalion
of inlornaI nogalivo prossuro (vacuum) during draining.
Irossuro vossoIs and/or piping sysloms llal
viII loId llo losl valor for moro llan 10 days, vlollor
or nol llo losl Iiquid is prossurizod, slouId bo lroalod
vill a corrosion inlibilor and biocido. A corrosion ongi-
noor slouId bo consuIlod.
If furllor drying is nocossary, llo uso of lol
air or lol nilrogon slouId bo considorod.
If compIolo drainago of auslonilic slainIoss
slooI vossoIs and/or piping sysloms is nol possibIo, llo
compononls slouId bo fIuslod vill Iov clIorido (Ioss
llan 5 ppm) valor.
Aflor compIolion of llo losl, llo vossoI and/
or piping syslom slaII bo roslorod lo ils oporaling condi-
lion. Tlis incIudos, bul is nol Iimilod lo, paras.
6.1(l)(10)(a) llrougl 6.1(l)(10)(f).
AII fIangod joinls bIindod for prossuro losling
slaII bo roassombIod vill novgasIols andligllonodpor
appIicabIo spocificalions. Considoralion slaII bo givon
lo ASMI ICC-1,
.
AII slrainors conlainod in llo piping syslom
slouId bo romovod, cIoanod, and roinslaIIod.
Tomporary lravoI slops inslaIIod in spring
supporls slouId bo romovod.
Vonl and bIood connoclions llal voro
inslaIIod for losling purposos onIy slouId bo pIuggod
using maloriaIs and mollods por llo appIicabIo spocifi-
calion. Considoralion slaII bo givon lo soaI voIding
vlon nocossary.
RoIiof or safoly vaIvos llal voro isoIalod for
llo losl slaII lavo llo isoIaling dovicos (o.g., gags, sIip
bIinds, olc.) romovod.
Ixpansion joinls llal voro IocIod lo provonl
damago during llo prossuro losl slaII bo unIocIod.
6.2 Pneumatic Pressure 1est eI Pressure vesseIs er
Piping
Wlon a lydroslalic prossuro losl cannol bo por-
formod por para. 6.1 (soo para. 3.4.1), a pnoumalic pros-
suro losl may bo porformod.
Nilrogon slouIdbo llo losl modiumsinco il cannol
supporl combuslion. AIlornalivoIy, cIoan, dry, oiI-froo
air mooling llo roquiromonls of CIass 1, 2, or 3 air por
ISO 8573-1:2001,
, slouId bo usod vill a dov poinl
slouId bo usod vlon air is usod in any syslom llal
191
cannol bo vorifiod as boing froo of lydrocarbons sinco
llis couId rosuIl in llo formalion of an oxpIosivo mix-
luro. Wlon nocossary, llo dosign sorvico fIuid can bo
usod for pnoumalic prossuro losling.
Tlo fabricalion and in-sorvico inspoclion rocords
aIong vill any nocossary oporalionaI rocords slouId bo
roviovod prior lo losling lo dolormino if llo prossuro
compononl/syslom las oxporioncod a crodibIo dolorio-
ralion moclanism. Considoralion slouId bo givon lo
lov oacl moclanism couId manifosl ilsoIf.
Tlo inspoclion rocords slouId bo roviovod for
llinning boyond llo spocifiod Iimil. If llinning las
occurrod boyond llo spocifiod corrosion aIIovanco, an
onginooring ovaIualion slaII bo porformod.
Tlo compononl/syslom may lavo boon dam-
agod by moclanicaI moans sucl as ligl vibralion. Con-
sidoralion slouId bo givon lo inspocling llo onliro
syslom prior lo losling lo IooI for ovidonco of damago.
Compononls fabricalod frombrillIo maloriaIs sucl
as casl iron and ducliIo iron slaII nol bo pnoumalicaIIy
prossuro loslod unIoss llo foIIoving roquiromonls aro
adlorod lo:
llo prossuro losl doos nol oxcood MAWI
addilionaI NDI, sucl as Acouslic Imission
(AI) losling, is porformod aIong vill llo prossuro losl
llo procoduros from para. 6.2.1 aro foIIovod
Tlo maximum caIcuIalod slorod onorgy of any
vossoI or piping syslom boing pnoumalicaIIy prossuro
loslod slouId nol bo groalor llan 271 000 000 }
(200,000,000 fl-Ib). If llo caIcuIalod slorod onorgy is
groalor llan 271 000 000 } (200,000,000 fl-Ib), llon ono
of llo foIIoving slaII occur:
Tlo syslom slaII bo dividod inlo smaIIor voI-
umos sucl llal oacl subsyslom las a slorod onorgy nol
groalor llan 271 000 000 } (200,000,000 fl-Ib).
A minimum dislanco slaII bo caIcuIalod por
Mandalory Appondix III, oq. (III-1), and llis dislanco
slaII bo adlorod lo.
A barricado por para. 6.2(g) slaII bo inslaIIod.
A dolaiIod lazard anaIysis slouId aIso bo por-
formod lo ovaIualo llo risI associalod vill llo roIoaso
of slorod onorgy. Soo MandaloryAppondix IVfor consid-
oralions roIalivo lo risI ovaIualion. Iaclors lo considor
in llis anaIysis slouId incIudo:
any damago moclanisms idonlifiod by roviov
of fabricalion or in-sorvico inspoclion rocords aIong vill
oporalionaI rocords
llo MDMT of llo compononls boing prossuro
loslod, and ils roIalivo comparison lo llo losl lompora-
luro lo addross llo risI of brillIo fracluro
llo slross IovoI of llo syslom vliIo undorgoing
a losl
llo amounl of nondoslruclivo oxaminalion por-
formodon voIds llal lavo nol proviousIy boon subjoclod
lo a lydroslalic or pnoumalic prossuro losl

ollor simuIlanoous inspoclion mollods boing
porformod during llo prossuro losl sucl as Acouslic
Imission (AI) losling
prossuro vavo from polonliaI bIasl
sizo of fragmonls rosuIling from faiIuro of sys-
lom and dislanco of lravoI
Ior prossuro losls vloro llo risI of injury from
polonliaI fragmonls, slocI vavos, or ollor consoquoncos
of any prossurizod syslom faiIuro is dolorminod lo bo
unaccoplabIo, a Iimilod accoss aroa and prossuro conlroI
poinl slouId bo oslabIislod. Tlo minimum dislanco
fromllo boundary of llis aroa lo llo prossurizod compo-
nonl slouId bo caIcuIalod according lo llo procoduro of
Mandalory Appondix III.
Wlon llo spacing roquiromonls doscribod in
Mandalory Appondix III aro nol acliovabIo, considor-
alion slouId bo givon lo llo dosign, fabricalion, and
inslaIIalion of an aIlornalivo barricado capabIo of vill-
slanding llo bIasl of slorod onorgy villin llo syslom.
Soo aIso para. 6.2(o).
Ovorprossuro roIiof proloclion slaII bo providod.
Tlo sol prossuro of a prossuro roIiof dovico slouId bo
nol moro llan llo groalor of
llo losl prossuro pIus 70 IIa (10 psi), or
110 of llo losl prossuro
Tlo losl prossuro for a pnoumalic prossuro losl for
oquipmonl slaII bo according lo llo originaI codo of
conslruclion, considoring aIso any subsoquonl ongi-
nooring anaIysis as doomod nocossary.
If llo roquiromonls of llo originaI codo of conslruc-
lion aro nol avaiIabIo, llo losl prossuro for a pnoumalic
prossuro losl for prossuro vossoIs slaII bo
1.1
(3)
vloro
maximum aIIovabIo vorIing prossuro
from llo Manufaclurors Dala Roporl. If
unInovn, uso llo vossoIs dosign or ralod
prossuro.
losl prossuro lo bo usod


ralio of aIIovabIo slrossos, llo Iovosl vaIuo

slaII bo usod in oq. (3) for aII maloriaIs
considorod
1.1 llo losl faclor
Tlo losl prossuro for a pnoumalic prossuro losl for
piping sysloms slaII bo
1.1 (4)
192
vloro
llo inlornaI dosign prossuro of llo piping
syslom
llo losl prossuro lo bo usod

1:1 llo losl faclor
Tlo slorod onorgy of llo oquipmonl or piping sys-
lom undor pnoumalic prossuro slouId bo caIcuIalod and
convorlod lo oquivaIonl pounds of TNT(TrinilroloIuono)
using llo oqualions slovn in Mandalory Appondix II.
Tlo vaIuo caIcuIalod may bo usod for aIlornalivo safo
dislanco caIcuIalions as por Mandalory Appondix III.
NOTI: Tlo slorod onorgy vaIuo of 271 000 000 } (200,000,000 fl-
Ib) is oquivaIonl lo an oxpIosivo onorgy of 127 Ib of TNT. RisI
ovaIualion may aIso bo roquirod, soo Mandalory Appondix IV and
para. 6.2(d).
6.2.1 Pneumatic 1est Precedures. Tlo iloms spoci-
fiod in paras. 6.2.1.1 llrougl 6.2.1.5 (Slops 1 llrougl
5) slouId bo considorod vlon dovoIoping pnoumalic
prossuro losl procoduros for vossoIs or piping sysloms.
6.2.1.1 5tep 1
Raiso prossuro lo llo Iossor of 170 IIa (25 psi) or
25 of losl prossuro.
BIocI in suppIy and loId for 10 min.
VisuaIIy inspocl syslom for IoaIs.
If IoaIs aro discovorod, roIoaso prossuro, ropair,
and rolurn lo Slop 1.
If no IoaIs aro discovorod, procood lo Slop 2.
6.2.1.2 5tep 2. GraduaIIy incroaso syslom pros-
suro lo 50 of llo losl prossuro as foIIovs:
Incroaso from prossuro in Slop 1 by 350 IIa (50 psi)
or lo 35 losl prossuro, vliclovor is groalor. HoId for
a minimum of 3 min lo aIIov slrains lo oquaIizo. Con-
linuo lo incroaso by 350 IIa (50 psi) incromonls unliI
llo syslom prossuro is al 50 losl prossuro.
HoId al 50 losl prossuro for a minimum of 10
min. Obsorvo prossuro gago for Ioss of syslom prossuro.
If prossuro Ioss oxcoods 10 of losl prossuro, llo syslom
prossuro slouId bo roducod lo 25 losl prossuro and
clocI for IoaIs.
If no Ioss of prossuro is doloclod, subj ocl lo
approvaI of llo inspoclor, procood lo Slop 3.
6.2.1.3 5tep 3
GraduaIIy incroaso syslom prossuro in incromonls
of 10 of losl prossuro. Al oacl incromonl, bIocI suppIy
and obsorvo prossuro gago for 5 min.
If prossuro Ioss is obsorvod, roduco prossuro lo 25
losl prossuro and clocI for IoaIs. If nocossary, roIoaso
prossuro and porform nocossary ropairs. Rolurn lo
Slop 1.
Onco fuII losl prossuro is roaclod, bIocI suppIy
and obsorvo prossuro gago for a minimum of 10 min.

Roduco syslom prossuro lo llo foIIoving appIica-
bIo prossuro:
llo losl prossuro dividod by llo losl faclor for
vossoIs |soo oq. (3)]. If lloro is no losl faclor avaiIabIo,
uso 4/5 losl prossuro.
dosign prossuro for piping.
6.2.1.4 5tep 4
Conducl a compIolo inspoclion for IoaIago of llo
vossoI or piping syslom, or boll, al Iocalions sucl as
fIangos, voId joinls, and llroadod connoclions.
NOTI: Il is assumod llal llo inlogrily of llo prossurizod syslom
las boon provon by para. 6.2.1.3(b) and llo barricados roquirod by
para. 6.2(o) can bo safoIy passod.
If no IoaIago is discovorod, roIoaso syslom
prossuro.
If IoaIago llal is nol accoplabIo is discovorod,
roIiovo aII syslom prossuro and ropair. Ropoal Slops 2
and 3.
6.2.1.5 5tep 5. Aflor compIolion of llo losl, llo
vossoI or piping syslom, or boll, slaII bo roslorod lo ils
dosign condilion. Tlis incIudos, bul is nol Iimilod lo,
llo foIIoving:
AII fIangod joinls bIindod for prossuro losling slaII
bo roassombIod vill nov gasIols and ligllonod por
appIicabIo spocificalions. Considoralion slouId bo givo
lo ASMI ICC-1 guidoIinos.
Vonl and bIood connoclions llal voro inslaIIod for
losling purposos onIy slouId bo pIuggod using maloriaIs
and mollods por llo appIicabIo spocificalion. Considor-
alion slaII bo givon lo soaI voIding vlon nocossary.
6.3 1ightness 1est
A ligllnoss losl may bo porformod lo dolocl IoaIs
al various Iocalions villin a prossuro syslom. Il may bo
porformod on sysloms llal lavo proviousIy boon pros-
suro loslod, for cIosuro voIds of piping sysloms, on lubo-
lo-luboslool joinls, and on sysloms oxomplod from
lydroslalic or pnoumalic losling. ASMI Soclion V,
ArlicIo 10 providos informalion on a varioly of IoaI
losling mollods.
A sonsilivo IoaI losl por ASMI B31.3 is llo pro-
forrod mollod for conducling a ligllnoss losl.
Tlo appIiod losl prossuro for vossoIs and piping
slouId nol oxcood 35of llo dosign prossuro. Hovovor,
IoaIago al fIangod joinls may bo ovidonl al mucl Iovor
prossuros vlon using sonsilivo IoaI doloclion mollods,
lloroforo, llo minimumlosl prossuro slouId bo spocifiod
vlicl onabIos llo losl sonsilivily roquiromonls lo bo mol.
Wloro llo consoquoncos of IoaIago of llo procoss
modium aro accoplabIo, an in-sorvico IoaI losl may bo
porformod as a ligllnoss losl using llo procoss modium
during llo slarl-up of llo syslom.
6.3.1 Pneumatic 1ightness 1est Precedures. Tlo
iloms spocifiod in paras. 6.3.1(a) llrougl 6.3.1(f) slouId
193
bo considorod vlon dovoIoping pnoumalic ligllnoss
losl procoduros for vossoIs or piping sysloms.
CIoan, dry, oiI-froo air slouId bo usod as llo losl
modium, oxcopl in sysloms vlicl cannol bo vorifiod
as froo from lydrocarbons. Ior llis silualion, nilrogon
slouId bo usod as llo losl modium |soo para. 6.2(b)].
To minimizo llo slorod onorgy of a syslom, llo
maximum losl prossuro slouId bo nol moro llan 35
of llo dosign prossuro of llo vossoI or piping syslom.
Tlo losl prossuro slouId bo no Ioss llan llo Iossor of
105 IIa (15 psi) or 25 of llo syslom dosign prossuro.
Tlo syslom prossuro slouId bo graduaIIy
incroasod unliI llo syslom prossuro is llo Iossor of
170 IIa (25 psi) or 25 of llo losl prossuro. HoId al llis
prossuro Iong onougl lo conducl a proIiminary inspoc-
lion for IoaIs.
Syslom prossuro slouId bo graduaIIy incroasod in
incromonls of 10 of losl prossuro, loIding for 30 soc
lo 1 min al oacl incromonl. HoId al finaI losl prossuro
and compIolo a llorougl inspoclion for IoaIago using
llo Gas and BubbIo losl mollod spocifiod in ASMI
Soclion V, ArlicIo 10, or ollor mollod of oquaI or bollor
sonsilivily.
If IoaIago is discovorod and a joinl noods lo bo
ligllonod, roduco syslom prossuro lo llo Iossor of 50
of losl prossuro or 170 IIa (25 psi) and ligllon.
Aflor compIolion of llo losl, llo vossoI and/or
piping syslom slaII bo roslorod lo ils oporaling
condilion.
7 kFkhC5
AII RI 571, Damago Moclanisms Affocling Iixod
Iquipmonl in llo Irocoss Induslry
AII RI 580, RisI Basod Inspoclion
Slrool, NW, Waslinglon, DC 20005-4070.
ASMI BoiIor and Irossuro VossoI Codo, Soclion II,
Iarl D Iroporlios
Division 1 Unfirod Irossuro VossoIs
ASMI B16.5, Iipo IIangos and IIangod Iillings
ASMI B31.3, Irocoss Iiping. Soo aIso Appondix I
lloroin for considoralions of damago moclanisms.
ASMI ITC 19.2, Irossuro Moasuromonl, Inslrumonls
and Apparalus

Rocommondod Iraclico SNT-TC-1A
IubIislor: Amorican Socioly for Nondoslruclivo Tosling
(ASNT), 1711 ArIingalo Iano, I.O. Box 28518,
CoIumbus, OH 43228-0518
NDT SoIulion: Worriod Aboul IoaIs` Donl Iainl
Boforo Hydrolosling, }on I. Baloy, MaloriaIs
IvaIualion, VoIumo 51, Numbor 9, Soplombor 1993,
pp. 980-982.
WoIding Rosoarcl CounciI BuIIolin 490, Damago
Moclanisms Affocling Iixod Iquipmonl in llo IossiI
194
IIoclric Iovor Induslry, }onallan D. Dobis and
David N. Ironcl, }uIy 2, 2004.
Moclanisms Affocling Iixod Iquipmonl in llo
IuIp and Iapor Induslry, }onallan D. Dobis and
David C. Bonnol, }uIy 2, 2004.
Moclanisms Affocling Iixod Iquipmonl in llo
Rofining Induslry, }onallan D. Dobis, }. I. CanlvoII
and Marlin Iragor, }uIy 2, 2004.
IubIislor: WoIding Rosoarcl CounciI (WRC), I.O. Box
201547, SlaIor Hoiglls, OH 44120

Pressure]Leak 1esting
195

196

5tered nergy CaIcuIatiens Ier Pneumatic Pressure 1est
Tlo slorod onorgy of llo oquipmonl or piping syslom
slouId bo caIcuIalod and convorlod lo oquivaIonl IiIo-
grams (pounds) of TNT (TrinilroloIuono) using llo foI-
Ioving oqualions:
1/(
)
1
(II-1)
vloro
slorod onorgy, } (fl-Ib)
ralio of spocific loal for llo losl fIuid
absoIulo almosploric prossuro, 101 IIa

(14.7 psia)
absoIulo losl prossuro, Ia (psia)

lolaI voIumo undor losl prossuro, m
3
(fl
3
)
Wlon using air or nilrogon as llo losl modium
( 1.4), llis oqualion bocomos
2.5
)
0.286
(II-2)
and
TNT
4266920
(Ig)
(II-3)
197
vloro
slorod onorgy, }
absoIulo almosploric prossuro, 101 000 Ia
absoIulo losl prossuro, Ia

lolaI voIumo undor losl prossuro, m
3
Ior U.S. Cuslomary unils using air or nilrogon as llo
losl modium ( 1.4), llis oqualion bocomos
360
)
0.286
(II-4)
and
TNT
1488617
(Ib)
(II-5)
vloro
slorod onorgy, fl-Ib
absoIulo almosploric prossuro, 14.7 psia
absoIulo losl prossuro, psia

lolaI voIumo undor losl prossuro, fl
3
Soo aIso paras. 6.2(o) and 6.2(f) of ArlicIo 5.1.

5aIe istance CaIcuIatiens Ier Pneumatic Pressure 1est
Tlo minimum dislanco bolvoon aII porsonnoI and llo
oquipmonl boing loslod slaII bo llo groalor of
llo foIIoving:
30 m for 135 500 000 }
60 m for 135 500 000 } 271 000 000 }
100 fl for 100,000,000 fl-Ib
200 fl for 100,000,000 200,000,000 fl-Ib
llo foIIoving oqualion:

scaIod
(TNT)
1/3
(III-1)
vloro
slorod onorgy as caIcuIalod by oq. (II-1)
or (II-2)
acluaI dislanco from oquipmonl
SCAIID
scaIod consoquonco faclor, vaIuo for
oq. (III-1) slaII bo 20 m/Ig
1/3
(50 fl/Ib )
or groalor
TNT onorgy moasurod in TNT, Ig (Ib), dolor-
minod from oq. (II-3) or (II-5)
198
1abIe III-1
1]3
1]3

20 50 . . . 6lass wlndcws
12 30 Fardrum rupture Ccncrete blcck panels
6 15 Lung damage 8rlck walls
2 5 Fatal . . .
Ior sysloms vloro 271 000 000 } (200,000,000 fl-Ib),
llo roquirod dislanco slaII bo caIcuIalod by oq. (III-1).
If llo minimum caIcuIalod dislanco cannol bo
oblainod, an aIlornalivo vaIuo for
SCAIID
may bo closon
basod on TabIo III-1 for uso in oq. (III-1). Soo aIso
para. 6.2(g).
Ior oxampIo, lo provonl Iung damago, llo dislanco a
porson is fromllo oquipmonl slouIdrosuIl in an
SCAIID
vaIuo of moro llan 6 m/Ig
1/3
(15 fl/Ib
1/3
). Nolo llo
slrucluraI damago llal can occur, vlicl slaII bo
considorod.

kisk vaIuatien Censideratiens Ier Pneumatic Pressure 1est
Wlon considoring llo risI anaIysis faclors Iislod in
para. 6.2(f ), il slouId bo romomborod llal risI is a
lvo-dimonsionaI combinalion of probabiIily (or IiIoIi-
lood) andconsoquonco. RisI is llo moasuro of llo polon-
liaI for larm or Ioss (i.o., lazard) llal rofIocls llo
IiIoIilood (or froquoncy) and sovorily of an advorso
offocl lo loaIll, proporly, or llo onvironmonl. If probabiI-
ily and consoquonco aro dofinod quanlilalivoIy (i.o.,
numoricaI vaIuos aro assignod), risI is llo producl.
RisI IrobabiIily Consoquonco (IV-1)
In a quaIilalivo assossmonl, a malrix is lypicaIIy usod
lo combino probabiIily and consoquonco. Considoralion
slouId bo givon lo llo IovoI of risI llal is accoplabIo
vlon porforming pnoumalic losls. Roforonco AII RI 580
for uso of risI assossmonl in dolormining llo accoplabIo
IovoIs of risI associalod vill pnoumalic losling.
In rovioving oq. (IV-1), il is cIoar llal ovon llougl
llo consoquonco may bo significanl, if llo probabiIily is
vory Iov, llo risI may bocomo accoplabIo. Ior oxampIo,
llo consoquonco of an airIinor crasling is significanl in
llal il viII mosl IiIoIy rosuIl in sorious injury or doall
lo llo passongors aIong vill major damago or lolaI Ioss
of llo aircrafl. Hovovor, llo probabiIily of llo airIinor
crasling is vory Iov, llus, llo pubIic accopls llo risI
associalod vill airIino lravoI.
RisI considoralions can bo appIiod lo pnoumalic losl-
ing aIso. IxampIos may incIudo
199
a nov auslonilic slainIoss slooI piping syslom llal
las boon lydroslalicaIIy loslod during slop fabricalion
vill llo oxcoplion of four finaI fioId assombIy circumfor-
onliaI bull voIds. Tlo piping syslom las a lolaI voIumo
llal rosuIls in an onorgy IovoI groalor llan 271 000 000 }
(200,000,000 fl-Ib), lovovor, il is nol foasibIo lo soparalo
llo piping syslom inlo smaIIor soclions for losling, nor
is il foasibIo lo inslaII bIasl barriors. By porforming voIu-
molric oxaminalion sucl as UT or RT and dolormining
llo fioId voIds aro froo of rojoclabIo indicalions, llo risI
associalod vill a fuII pnoumalic prossuro losl of llis
syslom may bo doomod accoplabIo.
an oxisling carbon slooI vossoI vill an MDMT
boon inslaIIod foIIoving aII roquiromonls of llo originaI
Codo of Conslruclion. Tlo vossoI las a lolaI voIumo
llal rosuIls in an onorgy IovoI groalor llan 271 000 000 }
(200,000,000 fl-Ib), lovovor, il is sliII dosirod lo porform
a prossuro losl lo clocI llo inlogrily of llo voId and
oblain llo ollor bonofils of prossuro losling. Il is nol
foasibIo lo inslaII bIasl barriors. By porforming voIumol-
ric oxaminalion sucl as UT on llo nozzIo allaclmonl
voId and dolormining llo voId is froo of rojoclabIo indi-
calions, aIong vill vorificalion by inspoclion llal llo
vossoI is in a IiIo-nov condilion, llo risI associalod vill
a fuII pnoumalic prossuro losl of llis vossoI may bo
doomod accoplabIo.
(08)

ArticIe 5.2
hendestructive xaminatien in Lieu eI Pressure 1esting Ier
kepairs and AIteratiens
1 5CkIP1I0h
1.1 ackgreund
Tlis ArlicIo providos aIlornalivos lo prossuro losling
aflor ropairs or aIloralions. A prossuro losl in ilsoIf is a
usofuI looI vill rospocl lo novIy conslruclod oquipmonl.
AppIicalion of a prossuro losl, lo oquipmonl llal las
boon in sorvico for somo limo, is a mallor llal roquiros
carofuI considoralion of a varioly of faclors invoIvod.
Tloro aro inslancos vloro llo appIicalion of a prossuro
losl is nol dosirabIo, sucl as, llo appIicalion of a prossuro
losl may croalo damago.
1.2 AppIicatien
Tlis ArlicIo appIios lo oquipmonl for vlicl
NDI providos bollor assuranco of inlogrily in
fuluro oporalion for oIovalod lomporaluro or cycIic opor-
alion vloro cracI inilialion and propagalion is a con-
corn. Iargo fIavs may nol rosuIl in faiIuro during a
prossuro losl bul may propagalo in cycIic or croop
sorvico.
a prossuro losl is nol praclicaI and NDI can bo
slovn lo provido approprialo inlogrily assuranco. A
prossuro losl of oquipmonl llal las boon ropairod is
primariIy a IoaI losl, or, in somo casos, a losl for gross
fabricalion fIavs llal couId compromiso slrucluraI
inlogrily. SlrucluraI inlogrily of llo dosign is usuaIIy
nol an issuo for ropairs. Ivon for mosl aIloralions, llo
inlogrily of llo dosign can bo vorifiod by onginooring
anaIysis.
a prossuro losl is praclicaI, bul NDI can bo slovn
lo provido oquivaIonl inlogrily assuranco. In llis caso,
ovoraII cosl may bo a major considoralion. Il is ossonliaI
llal llo approprialo NDI bo porformod basod on llo
damago moclanisms anlicipalod during ropairs or
aIloralions.
1.3 Pressure 1esting
Irossuro losling consisls of llroo primary mollods.
Tlo fIuid usod is lypicaIIy valor,
lovovor, anollor suilabIo Iiquid can bo subslilulod if
lloro is a risI of damago duo from any advorso offocls
of laving valor in llo syslom.
Tlis is porformod in somo silua-
lions vloro llo prosonco of any valor or voigll of llo
valor in llo syslom is an issuo. Tlo pnoumalic losl is
200
polonliaIIy lazardous duo from llo slorod onorgy of llo
comprossod gas.
Tlis is a combinalion of llo
lvo ollor losl mollods. ArlicIo 5.1 slouId bo roforrod
for prossuro losling issuos and procaulions.
1.4 hendestructive xaminatien (h)
NDI las boon dofinod as comprising lloso oxamina-
lion mollods (soo Mandalory Appondix I) usod lo oxam-
ino an objocl, maloriaI, or syslom villoul impairing ils
fuluro usofuInoss. Il is usod lo invosligalo llo maloriaI
and compononl inlogrily.
Dolormining llo slrucluraI inlogrily of a prossuro-
rolaining dovico or compononl can bo accompIislod by a
procoss invoIving a quanlilalivo onginooring ovaIualion
coupIod vill NDI lo oblain curronl vaII llicInossos
and provido doloclion and sizing of any in-sorvico fIavs
or cracIs (NalionaI Board BuIIolin, VoIumo 61).
1.5 Pressure 1est
1.5.1 keasens Ier Pressure 1esting in hew
Censtructien
ClocIs for IoaIago of moclanicaI and voIdod
joinls
May avoid an in-sorvico faiIuro and associalod
safoly issuos
Scroons oul gross dosign, maloriaI, fabricalion
doficioncios
Roducos llo slross-muIlipIying capabiIily of slarp
nolclos, molaIIurgicaI dofocls, disconlinuilios (fIav lip
bIunling)
Irovidos moclanicaI slross roIiof
AIso rofor lo ArlicIo 5.1, para. 3.2 of llis documonl
1.6 h Metheds
Tlo foIIoving is a Iimilod Iisl of llo moro common
aIlornalivo NDI mollods. Mandalory Appondix I con-
lains a labIo llal comparos NDI mollods, proporlios
sonsod or moasurod, lypicaI disconlinuilios doloclod,
roprosonlalivo appIicalions, advanlagos, andIimilalions.
Rofor lo soclion 5 of llis Arl icIo for oxaminali on
roquiromonls.
1.6.1 AIternative h Metheds: veIumetric
Radiograply
UIlrasonic Sloar-vavo

Aulomalod UIlrasonics, sucl as limo-of-fIigll-
diffraclion (TOID) and Ilasod Array
1.6.2 AIternative h Metheds: 5urIace
Magnolic IarlicIo
Iiquid Ionolranl
Iddy Curronl
Magnolic IIux IoaIago
1.7 rittIe Fracture kisk
Iorforming prossuro losls of an in-sorvico dovico or
compononl vill inadoqualo fracluro louglnoss couId
rosuIl in brillIo fracluro. Onco a dovico or compononl
las boon subjoclod lo a ono-limo (al nov conslruclion)
lydroslalic losl, anyaddilionaI lydroslalic losls ovor llo
Iifo of llo compononl viII sorvo minimaI usofuI purposo
rogarding slrucluraI inlogrily or bonofils of rodislribu-
lion of slrossos. In addilion, porforming a lydroslalic
losl abovo llo normaI vorIing prossuro of an in-sorvico
compononl can rosuIl in significanl oxposuro lo brillIo
fracluro ospociaIIy if llo maloriaI of conslruclion las
boon subjoclod lo somo dogroo of ombrillIomonl undor
normaI sorvico condilions or possossos poor fracluro
louglnoss as a rosuIl of slooI moIling praclicos or con-
lains an undoloclod crilicaI fIav from in-sorvico oxpo-
suro or viII bo prossuro loslod boIov llo DTB lransilion
lomporaluro of any compononl.
2 LIMI1A1I0h5
2.1 AIternative kequirements: Part 1 eI A5M PCC-2
2.2 kepaired er AItered Pressure quipment
Tlo lorms ropairod and aIlorod aro as dofinod in
llo Nal ionaI Board Inspoclion Codo (NBIC),
ANSI/NB-23 Appondix 4, or AII 510 and AII 570 for
prossuro vossoIs and piping.
2.3 xampIes where Pressure 1est May e
InadvisabIe
2.3.1 Feundatien er 5uppert 5tructure. Wloro llo
foundalion or supporling slrucluro las nol boon
dosignod lo carry llo voigll of Iiquid fiIIod prossuro
oquipmonl.
2.3.2 bndesirabIe keactiens er Censequences. A
safoly concorn vloro llo appIicalion of losl fIuids couId
Ioad lo an undosirabIo roaclion vill llo rosiduo of fIuids
conlainod in llo prossuro oquipmonl.
2.3.3 esign keasens
Wloro llo dosign of llo prossuro oquipmonl is
basod on ollor faclors, sucl as bonding vloro slrossos
duo lo prossuro may nol bo govorning
201
Wloro a vossoI for vlicl llo llicInoss of llo pros-
suro boundarycompononls is govornodby oxlornaI pros-
suro (bucIIing) considoralions
2.3.4 Painting]Ceating]Lining Issues. Wloro
painling/coaling/Iining couId masI IoaIs llal vouId
ollorviso lavo boon doloclod during a prossuro losl.
AIso incIudos damago lo rofraclory or ollor insuIaling
inlornaI maloriaIs, and damago lo inlornaI Iinings.
2.4 kepairs and AIteratiens Ier which Pressure
1esting is het hermaIIy kequired (Ah5I]h-23)
Tlo foIIoving lypos of ropairs and/or aIloralions may
bo oxompl from prossuro losling or vloro prossuro losls
may bo oplionaI doponding upon llo noods of llo
ovnor-usor:
voIding or brazing llal doos nol ponolralo llo
prossuro boundary al any poinl
soaI voIds
cIadding appIicalion/ropairs
lard surfacing
voIding lo fIango soaling surfacos, vlon Ioss llan
50 of llo axiaI llicInoss is ropIacod by voIding
lubo-lo-luboslool voIds providod Ioss llan 10 of
llo lolaI numbor of lubos aro ropIacod al any limo aflor
a fuII oporalionaI cycIo
lubo pIugging or sIooving of loal oxclangors,
sloam gonoralors, or boiIor lubos
lol lap fillings
3 5ICh
Soo para. 2.3.3 of llis ArlicIo.
4 FAkICA1I0h (kPAIk 0k AL1kA1I0h)
Nol appIicabIo lo llis ArlicIo.
5 XAMIhA1I0h h0h51kbC1Iv
XAMIhA1I0h (h)
Tlo spocific lypo and amounl of surfaco and/or voIu-
molric NDI llal slouId bo spocifiod in Iiou of prossuro
losling is al llo ovnor-usors discrolion, llo oxlonl of
vlicl slouId bo basod on llo risI of IoaI or faiIuro of
llo oquipmonl. Tlo NDI spocifiod noods lo malcl llo
IiIoIilood of llo lypo of dofocls llal couId occur vill
llo parlicuIar maloriaIs and voIding mollods in uso. Soo
para. 1.6 for llo moro common NDI mollods gonoraIIy
ompIoyod in Iiou of prossuro losling.
6 151IhC
Nol appIicabIo lo llis ArlicIo.

7 kFkhC5
AII 510-2006, Irossuro VossoI Inspoclion Codo:
Mainlonanco Inspoclion, Raling, Ropair, and AIlor-
alion
AII 570, In-Sorvico Inspoclion Codo for Irocoss Iiping
Soclion IV, Hoaling BoiIors
Soclion V, Nondoslruclivo Ixaminalion
Irossuro VossoIs
202
Soclion IX, QuaIificalion Slandard for WoIding and
Brazing Irocoduros, WoIdors, Brazors, and WoIding
and Brazing Oporalors
Codo Caso 2235
Box 2300, IairfioId, N} 07007-2300
Rocommondod Iraclico SNT-TC-1A
IubIislor: Amorican Socioly for Nondoslruclivo Tosling
(ASNT), 1711 ArIingalo Iano, I.O. Box 28518, CoIum-
bus, OH 43228-0518
GaIanos, Goorgo, Irossuro Tosling: Iacl and Iiclion,
NalionaI Board BuIIolin, VoIumo 61, Numbor 3,
IaII 2006

Cemparisen eI 5eIected h Metheds
203

204

205
lhTFhTlUhALLY LFFT 8LAhK
206

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Appondix II corroclod lo road

finaI conlorIino radius, mm (in.)

originaI conlorIino radius, mm (in.). (Radius

llicInoss of llo llicIor of llo lvo adjaconl bull

if llo firsl bull voId las boon slross-

fIuslod from llo syslom prior lo ropair incIudo lydro-

3.2.2.1 Pump 5eIectien. Tlo pump slalion usod

diamolor al mid-vaII of compononl, mm (in.)

circumforonliaI forco duo lo inlornaI prossuro,

IongiludinaI forco duo lo inlornaI prossuro,

lolaI circumforonliaI forco from aII Ioads,

circumforonliaI forco duo lo ollor appIicabIo

lolaI IongiludinaI forco from aII Ioads, N/mm

IongiludinaI forco duo lo ollor appIicabIo

radius al mid-vaII of compononl, mm (in.)

aIIovabIo forco on fiIIol voIds, N/mm

aIIovabIo baso molaI slross, MIa (psi)

lolaI aIIovabIo vorIing Ioad on llo pIug

lolaI aIIovabIo vorIing Ioad on llo sIol

finaI conlorIino radius of palcl pIalo, mm (in.)

originaI conlorIino radius of palcl pIalo (oquaIs

Fig. 2 IIect eI weId Area en 1ransverse 5hrinkage

4.2 weIding 1echnique

diamolor al mid-vaII of compononl, mm (in.)

circumforonliaI forco duo lo inlornaI prossuro,

IongiludinaI forco duo lo inlornaI prossuro,

lolaI circumforonliaI forco from aII Ioads,

circumforonliaI forco duo lo ollor appIicabIo

lolaI IongiludinaI forco from aII Ioads, N/mm

IongiludinaI forco duo lo ollor appIicabIo

radius al mid-vaII of compononl, mm (in.)

aIIovabIo forco on fiIIol voIds, N/mm

aIIovabIo baso molaI slross, MIa (psi)

caIcuIalod voId slross, MIa (psi),

vaII llicInoss of palcl pIalo, mm (in.)

finaI conlorIino radius of palcl pIalo, mm (in.)

originaI conlorIino radius of palcl pIalo (oquaIs

lonsiIo slross aroa, in.

minimum llroad sloar aroa for oxlornaI

nominaI diamolor of llo slud, in.

joinl officioncy of llo nozzIo nocI

j oinl officioncy of llo sloII |soo

loigll of insido of llal porlion of nozzIo

loigll of oulsido of llal porlion of nozzIo

Iongll of ongagomonl, in.

Insido radius of llo nozzIo undor considor-

aIIovabIo slross of slud boIl, psi

aIIovabIo slross of forging, psi

aIIovabIo slross of sloII, psi

roquirod llicInoss of llo sloII, in. |soo

roquirod llicInoss of a soamIoss nozzIo

sum of aroas conlribuling lo roinforco-

Ior UG-43(g) of ASMI BIVC Soclion VIII, Division

(llo nominaI diamolor of llo slud) or

slud maloriaI al dosign lomporaluro

(3.25 in.), llo roquirod

, Iongll of ongagomonl is adoqualo.

, bsing Criteria Frem

lonsiIo slross aroa of llroad

minimum llroad sloar aroa for oxlornaI