AB-513 Repair and Alteration Requirements

8/2/2019 AB-513 Repair and Alteration Requirements

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the pressure equipment safety authority

Pressure EquipmentRepair and Alteration

Requirements

AB-513

Issued 2011-06-21

Edition 2, Revision 0


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Issued2011-06-21 AB-513 Edition 2, Rev 0 i

Table of Contents

1.0 INTRODUCTION.....................................................................................................................2.0 DEFINITIONS..........................................................................................................................3.0 GOVERNING LEGISLATION AND REQUIREMENTS...........................................................4.0 REFERENCED CODES AND STANDARDS AND OTHERGOODENGINEERING PRACTICES..................................................................................................5.0 GENERAL ...............................................................................................................................6.0 QUALITY SYSTEM CERTIFICATE OF AUTHORIZATION PERMITS................................. 1

6.1 Repairs and Alterations Outside Alberta ...................................................................16.2 Repairs Inspected and Certified under an Owner-User s Quality

Management System Certificate of Authorization Permit ..........................................17.0 NOTIFICATION AND AUTHORIZATION OF REPAIR OR ALTERATION .......................... 1

7.1 Notification to ABSA for Repairs and Alterations to Pressure Vessels andBoilers .......................................................................................................................1

8.0 EQUIPMENT ASSESSMENT, WORK SCOPE AND REPAIR ANDALTERATION PROCEDURES (STRATEGIES)................................................................... 1

8.1 Root Cause that Prompted the Work ........................................................................18.2 Condition of the Item to be Altered or Repaired ........................................................18.3 Fitness-for-Purpose Evaluations ...............................................................................18.4 Preparation of the Work Scope .................................................................................18.5 Preparation of Repair and Alteration Procedures (Methods, Strategies) ..................18.6 Submission of Repair and Alteration procedures and design information

to ABSA.....................................................................................................................18.6.1 Alteration procedures for Boilers and Pressure Vessels ...........................................18.6.2 Repair Procedures for Boilers and Pressure Vessels ...............................................18.6.3 Repair and Alteration Procedures for Pressure Piping..............................................1

9. 0 QUALIFICATIONS OF INSPECTORS.................................................................................. 110.0 WELDING.............................................................................................................................. 1

10.1 Welding and Brazing Procedures..............................................................................110.2 Welders .....................................................................................................................111.0 EXAMINATION, INSPECTION AND CERTIFICATION OF REPAIRS AND

ALTERATIONS OF BOILERS AND PRESSURE VESSELS............................................... 111.1 Inspection and Test Plan (ITP)..................................................................................111.2 Inspection and Certification .......................................................................................111.3 Inspection and Certification Activities ........................................................................111.4 Boilers and Pressure Vessels Repair and Alteration Report, AB-40.........................211.5 Repair or Alteration Nameplate .................................................................................2

12.0 EXAMINATION, INSPECTION AND CERTIFICATION OF REPAIRS ANDALTERATIONS TO PIPING AND FITTINGS........................................................................ 2

13.0 HOT TAPPING ...................................................................................................................... 2APPENDIX 1 ......................................................................................................................... 2REVISION LOG..................................................................................................................... 2


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Pressure Equipment Repair and Alteration Requirements

Issued 2011-06-21 AB-513 Edition 2, Rev 0 Page 3 of 26

1.0 INTRODUCTION

As provided for under Sections 12, 13 and 40 of the Pressure Equipment Safety

Regulation, the Pressure Equipment Safety Administrator has issued DirectiveIB11-006to establish that this ABSA Document AB-513, Pressure Equipment Repairand Alteration Requirements, defines Alberta requirements for post-constructionrepair and alteration activities performed under a valid Certificate of AuthorizationPermit.

AB-513 applies to pressure equipment that is subject to theSafety Codes Actand isnot exempt from the Pressure Equipment Safety Regulation.

The Pressure Equipment Safety Regulation(PESR) establishes requirements thatmust be met by persons who own, operate, design, construct, install, repair, alter ormaintain pressure equipment or provide related services to ensure that the pressureequipment is safe for operation.

AB-513 is developed to provide detailed guidance for post-construction repair andalteration activities for pressure equipment safety.

This edition of AB-513 has been revised to reflect current industry-recognized goodengineering practices used for post-construction repairs and alterations of pressureequipment and to address improvements that were identified in the application of the

previous AB-513. The new edition also provides additional information to assiststakeholders in ensuring that repairs and alterations to an item of pressure equipmentrestore it to a safe working condition. This edition of AB-513 supersedes all previouseditions of this document.

Post-construction repairs and alterationsrefers to repairs and alterations to pressureequipment after all new construction inspection, stamping and certifications on therequired construction data reports have been completed.

API510, API570, NBIC Part 3, and ASME PCC-2 are widely-used and recognized

generally accepted codes and standards governing repairs and alterations that wouldapply for most industry sectors.Information from these publications and other relevantgood engineering practices has therefore been used in preparing theAB-513.Theyare referenced in the applicable AB-513 sections and provide guidance on repairmethods and other technical information that is used when the code of constructioncannot be followed because of its new construction orientation. This includesguidance such as: inspection requirements, NDE, alternate heat treatment methods,welding considerations and pressure test requirements.


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NBIC, API, and PCC codes and standards and similar publications are not adopteddirectly as regulations in Alberta. Their application is established through reference inthis document and other ABSA policy documents.The Safety Codes Act, regulationsand AB-513 requirements shall govern in the event that there is a conflict between

these requirements and any industry code and standard. It should also be noted thatNB and API standards state that their use is not permitted in conflict with anyprevailing jurisdictional requirements.

Particular attention is drawn to the ASME PCC-2 Standard Repair ofPressureEquipment andPiping. This standard has been issued by the ASME PostConstruction Committee and provides technical information, procedures, andrecommendations for repair methods that were determined to be recognized andgenerally accepted good engineering practice.

PCC-2 contains a caution that also applies for other engineering practices: "users ofthe articlesin this document are cautioned that these articles have been developedgenerically and are recommended for general application. They may not benecessarily suitable for all applications. Precautionary considerations are provided butshould not be considered all inclusive. Sound engineering practices and judgmentshould be used to determine the applicability of a specific method or part of a methodto a specific application. Each repair should be subject to an appropriate review byqualified personnel and this review should consider subsequent deterioration of therepaired component".

ABSA policy documents were developed through close cooperation with owners and

other stakeholders; their input has been invaluable in compiling this document. Inparticular, we would like to acknowledge the input from the following user groups thatrepresent the industry sectors in Alberta:

Alberta Refinery & Petrochemical Inspection Association (ARPIA)

Upstream Chief Inspectors Association (UCIA)

Contract Chief Inspectors Association (CCIA)

Generation Utilities Advisory Committee (GUAC)

Integrity Management Association Pulp Producers (IMAPP)

ABSA policy documents are living documents that are reviewed periodically to ensure

that they are aligned with current industry practices. We would welcome anysuggestions you have to improve this document. Please provide your comments to:

Mike Poehlmann,Manager of [email protected]


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2.0 DEFINITIONS

For the purpose of AB-513, the following definitions apply. Relevant definitions fromthe Alberta Safety Codes Actand Pressure Equipment Safety Regulationare also

included in this section.

ABSA refers to the pressure equipment safety authority authorizedby the Albertagovernment for the administration and delivery of all safety programs related topressure equipment under theSafety Codes Act.

ABSA Inspectoris an ABSA Safety Codes Officer(SCO)who holds the requiredsafety codes officer designation and designated powers under theSafety Codes Actandis competent to inspect the item of pressure equipment.

Actmeans the Alberta Safety Codes Actand the regulations made under this Act thatapply to pressure equipment.

Administratorshall mean the Administrator in the pressure equipment disciplineappointed under the Act.

Alterationmeans any change to an item of pressure equipment as described in theoriginal Manufacturer s Data Report that requires a change of design calculations orotherwise affects the pressure-containing capability of the item of pressureequipment. Non-physical changes such as a change in the maximum allowableworking pressure (internal or external) or design temperature of a pressure retaining

item is an alteration. A reduction in minimum design metal temperature is also analteration.

Boilers and pressure vessels-For ease of reading this document, the term boilersand pressure vessels shall also include fired-heater pressure coils, indirect firedheater coils and thermal fluid heaters.

Competent, in relation to a person, is defined as possessing the appropriatequalifications, knowledge, skills, and experience necessary to perform the work safelyin accordance with AB-513.

Damage mechanismis any type of deterioration encountered that can result in flawsor defects that can affect the integrity of pressure equipment; for example, corrosion,cracking, erosion, dents, and other mechanical, physical, or chemical impacts.

Equipment recordsinclude design information, data reports, inspection plans andintegrity assessment, repair, and alteration records.


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Inspectormeans, an ABSA Inspector, or a person who meets the qualification andcompetence requirements defined inAB-513 and is authorized to inspect and certify arepair or alteration under his or her employer s quality management systemCertificateof Authorization Permit.

inspector means, the in-service inspector which performs integrity assessments.

Inspection Companymeans a company that provides in-service inspection programservices and holds the required Alberta quality management systemCertificate ofAuthorization Permit to perform integrity assessments per PESR section 11(2).

IMSmeansIntegrity Management System, which is a system for ensuring that thepressure equipment is designed, constructed, installed, operated, maintained, anddecommissioned in accordance with the PESR.

NBIC-ANSI/NB-23 National Board Inspection Code.

Ownerincludes a lessee, a person in charge, a person who has care and control, anda person who holds out that they have the powers and authority of ownership or whofor the time being exercise the powers and authority of ownership.

Owner-useris an owner that has provided an Integrity Management System inaccordance with the Pressure Equipment Safety Regulationand has been issued aquality management system Certificate of Authorization Permit under PESRsection11(3).

Pressureequipmentmeans athermal liquid heating system and any containment foran expansible fluid under pressure, including, but not limited to, fittings, boilers,pressure vessels and pressure piping systems, as defined in the regulations.Note: Fired process heaters that contain an expansible fluid under pressure arecovered under this definition.

Process plantrefers to petrochemical, refining, upstream and mid-stream oil and gasprocessing facilities, kraft pulp and paper mills, chemical plants, power generationplants and other equipment that is not classed as public occupancy equipment.

Public occupancyisdefined as the occupancy of any facility where members of thegeneral public are likely to be present. This would include schools, offices, shoppingmalls, stores, arenas, pools, restaurants, hotels, etc.

Pressure piping systemmeans pipes, tubes, conduits, fittings, gaskets, bolting andother components that make up the system for the conveyanceof an expansible fluidunder pressure and may also control the flow of the fluid.


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Repairis defined as any work necessary to restore pressure equipment to a conditionsuitable for safe operation at the existing design conditions.

Repair organizationmeans a repair company or an owner-user who performs therepair or alteration and holds an Alberta quality managementCertificate ofAuthorization Permit for the scope of work to be undertaken.

Certificationmeans that all the applicable inspection and certification requirementscovered in this document have been completed and certified by the Inspector on theapplicable report. (AB-40 for boiler and pressure vessel repairs and alterations).

3.0 GOVERNING LEGISLATION AND REQUIREMENTS

Legislation that governs the pressure equipment discipline includes the following:

1.Safety Codes Act

2.Pressure Equipment Exemption Order(Alberta Regulation 56/2006)

3.Pressure Equipment Safety Regulation(Alberta Regulation 49/2006)

4.Power Engineers Regulation(Alberta Regulation 85/2003)

5.Pressure Welders Regulation(Alberta Regulation 169/2002)

6.Administrative Items Regulation(Alberta Regulation 16/2004)

The following documents have been issued to define requirements under thePressure Equipment Safety Regulation, that must be met for in-service pressureequipment.

AB-505 Risk-Based Inspection Requirements for Pressure EquipmentThis document defines requirements for the development and use of risk-basedinspection (RBI) to manage the integrity of the pressure equipment.

AB-506Inspection & Servicing Requirements for Pressure EquipmentThis specifies requirements for integrity assessments (in-service inspection) ofpressure equipment and pressure relief valve servicing.

AB-512 Owner User Pressure Equipment Integrity Management RequirementsThis specifies quality management system requirements for owners who are requiredto hold a Certificate of Authorization Permit under PESR section 11(3).

AB-512a Owner-User Scope and Responsibilities form. This form is used to define theresponsibility for key activities under the owner-user s program.


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AB-513 Pressure Equipment Repair and Alteration RequirementsThis covers inspection and certification and other requirements for repairs andalterations to pressure equipment.

AB-515 Requirements for Inspection CompaniesThis specifies quality management system requirements for inspection companiesthat are required to hold a Certificate of Authorization Permit for integrity assessmentunder PESR section 11(2).

AB-515a Inspection Company Authorized Scope form. This form is used to define theresponsibility for key activities under the Inspection Company s program.

AB-518 Pressure Piping Construction Requirements. This specifies qualitymanagement system requirements for persons who construct pressure piping.

AB-519 Pressure Piping Alternative Test Methods Procedure Requirements.

AB-520 Finite Element Analysis (FEA)Requirements Regarding the Use of FEA to Support a Pressure Equipment DesignSubmission.

IB02-002 Certification of In-Service Pressure Equipment Inspectors.

AB-516 The Pressure Equipment Safety Regulation User Guideprovides valuableinformation and guidance to assist stakeholders in meeting the requirements of the

Pressure Equipment Safety Regulationand in assuring the safe operation of theirpressure equipment.

The official versions of AB-513, other ABSA policy documents and AB-516 are postedon www.absa.ca. Directives and bulletins issued by the Administrator and othervaluable information are also posted on the ABSA website.

Note that per the Safety Codes Actsection 1(g), the term construction includesrepairs and alterations. Therefore, all applicable requirements established inregulations for construction, such as registration of welding procedures, the

requirements of the Pressure WeldersRegulations, and design registration also applyfor repairs and alterations.

4.0 REFERENCED CODES AND STANDARDS AND OTHER GOODENGINEERING PRACTICES

Theadopted codes and standards and other recognized and generally accepted goodengineering standardsthat are cited in AB-513 are listed below. A full listing of the
http://www.absa.ca/


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codes and standards that are adopted as regulationsis provided in PESRSection 6.

ASME Section I - Rules for Construction of Power Boilers

ASME Section IV Rules for Construction of Heating BoilersASME Section Vlll Div 1 Rules for the Construction of Pressure VesselsASME Section VIII Div 2 Alternative RulesASME Section VIII Div 3 Alternative Rules High Pressure VesselsASME Section IX Qualification Standard for Welding and Brazing Procedures,

Welders, Brazers, and Welding and Brazing OperatorsCSA B51 Boiler, pressure vessel, and pressure piping codeASME B31.1 Nonmandatory Appendix V Recommended practice for operation,

maintenance and modification of power piping systemsASME PCC-1 Guidelines for Pressure Boundary Bolted Flange AssemblyASME PCC-2 Repair of Pressure Equipment and PipingNBIC ANSI/NB 23 National Board Inspection Code(Part 3)API510 Pressure Vessel Inspection CodeAPI570 Piping InspectionCodeAPI577 Welding Inspection and MetallurgyAPI579 API-579-1/ASME FFS-1 Fitness for serviceAPI582 Recommended Practice and Supplementary Welding Guidelines for the

Chemical, Oil andGasIndustries.API2201 Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries

5.0 GENERAL

Repairs and alterations to pressure equipment shall conform, insofar as possible, tothe section and edition of the ASME Code most applicable to the work planned.TheCode edition and addenda of the original code of construction must be used for theallowable design stresses and design evaluation. Other design requirements, such asmaterial requirements, type and extent ofnon-destructive examination (NDE) andheat treatment must also meet the minimum requirements specified on the originalManufacturer s Data Report. Cautionary note: advances in technology based onservice history have resulted in significant changes in the construction Coderequirements for certain materials andother design requirements. These changes

must be considered when designing the alteration or repair.

To ensure the safe operation of the item being repaired or altered, the latest acceptedcode edition and addenda of the construction code, that the item was built to, isnormally used for the execution of work (e.g. material controls, welding, fabrication,quality control, performance and acceptance of NDE), as the current code editionsreflect advances in technology and experience.


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Issued 2011-06-21 AB-513 Edition 2, Rev 0 Page 10of 26

The code of construction shall be supplemented by the applicable good engineeringpractices for in-service equipment, as repairs and alterations often require additionalconsideration that is not provided for in the new construction code. Thesemightinclude:

- contamination of the base metal;- fluid service, environmental, and other welding considerations;- welded repairs may exacerbate the problem, e.g. repairs to H2S

equipment;- post weld heat treatment may not be possible;- welding method may be unique and require special welding techniques,

such as weld sequence to avoid distortion, and controlled depositionmethods;

- the time element is often critical;- weather conditions, etc;- pressure testing may be impractical.

All parties involved in repair and alteration activities (e.g. designers, owners, repairorganizations, inspectors, ABSA) must follow the applicable code of construction andcurrent recognized and generally accepted engineering practices that apply for thespecific type of equipment and its service. They must ensure that the requiredresources and competent persons are assigned to design the repair or alteration,execute the work and conduct all the examinations, inspections and other activitiesneeded to meet AB-513 and to ensure that the repaired or altered item is safe forcontinued operation at the design conditions.

6.0 QUALITY SYSTEM CERTIFICATEOF AUTHORIZATION PERMITS

PESR sections 11,12, and 13 cover requirements for quality management systemsand Certificate of Authorization Permits and PESR section 40 contains specificrequirements for repairs and alterations.

Repairs and alterations of pressure equipment installed in Alberta must be done by arepair organization that holds an Alberta QMS Certificate of Authorization Permit(CAP) for the scope of work that is to be undertakenperPESR section 11(1).

Note: This also applies for organizations who hold a National Board R Certificate ofAuthorization.

Organizations that repair and alter ASME Section VIII Division 2 or Division 3 vesselsmust also hold a valid ASME Certificate of Authorization for construction of Division 2or 3 vessels respectively.


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The QMS certificate holder must provide a documented system that identifies theactions needed to ensure that the repair or alteration restores the equipment to asafeworking condition and meets AB-513.Competent persons who have the appropriateknowledge and experience must be assigned to prepare and approve the repair or

alteration procedure, execute the work and perform all the required examinations.

Organizations that service, repair, set or seal pressure relief valves require aCertificate of Authorization Permit for these activities.Repair or alteration of otherfittings, that are repaired or altered in an existing pressure piping system or boiler orpressure vessel, are normally included under the authorized scope of the repairorganization s CAP and would be conducted and documented accordingly (eg. fittingrepairs in a piping system would be covered under a piping repair CAP anddocumented on an AB-83 form).

A current directory of Alberta quality system permit holders and their authorized scopeof work is posted on ABSA s website www.absa.ca.

6.1 Repairs and Alterations Outside Alberta

Repairs and alterations to boilers and pressure vessels done in another jurisdiction inCanada that are to be brought into Alberta must be done under a quality controlprogram acceptable to the jurisdiction, where the item is being repaired or altered, inaccordance with CSA B51.

Repairs and alterations to pressure vessels done outside of Canada shall be done by

an organization who holds the appropriate National Board R stamp and they mustprovide a NB repair or alteration report, certified by a NBcommissioned Inspector, toABSA.

6.2 Repairs Inspected and Certified under an Owner-User s Quality ManagementSystem Certificate of Authorization Permit

Owner-users who are required to hold a CAP under PESR section 11(3) and havedemonstrated that they have an appropriate organization, documented workprocesses and designated competent resources to manage repairs and alterations at

their facilities, may be authorized under their CAP to inspect and certify certainrepairs done at their plant sites.

The scope of repairs that an owner-user is authorized to inspect and certify undertheir CAP is listed on ABSA form AB-512a, and is based on the owner-user sorganization structure, the maturity of their quality management systems and therange of competent resources they have available.
http://www.absa.ca/


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Any contracted inspection services must be provided by an organization that has anAlberta CAP per PESR section 11(2) and ABSA authorization for the scopeof repairinspection that is to be done. This scope is defined on form AB-515a.Note: AB-506Appendix A provides guidance as to when an inspection company must hold a CAP.

AB-512 and AB-515 establish the quality management system requirements forowner-users and inspection companies.

Appendix 1 shows the scope of inspection and certification of repairs and alterationsof boilers and pressure vessels that can be done byan owner-userand what must beinspected and certifiedby ABSA.

7.0 NOTIFICATION AND AUTHORIZATION OF REPAIROR ALTERATION

All repairs and alterations mustbe authorized by a competent person (e.g. Inspector),designated by the owner prior to the start of work.

7.1 Notification to ABSA for Repairs and Alterations to Pressure Vessels and Boilers

PESR section 40(3) states that no repair shall be undertaken withoutthe prioragreement of a Safety Codes Officer and 40(6) requires that the owner must notify anABSA Safety Codes Officerreasonably in advance of each repair or alteration to aboiler, fired-heater pressure coil, thermal liquid heating system, or pressure vessel.When repairs are inspected under an owner-user s CAP, notification may be limited toensuring that the ABSA Inspector is made aware of the repair.

Note, the repair organization is required, under the terms of their Alberta qualityprogram Certificate of Authorization Permit, to notify an ABSA Inspector prior to thestart of each repair or alteration that they will be doing.

Notification of repairs and alterationswill assist ABSA in ensuring that all repairs andalterations are done in accordance with AB-513, and to complete their requiredinspection and certification activities when the inspection is not covered under thescope of an owner-user s CAP.

All alterations to boilers and pressure vessels and all repairs that are not inspected

and certified by an owner-user must be authorized, inspected and certified by anABSA Inspector. Refer to Section 11 of this document.

The Appendix 1 flowchart illustrates responsibilities for notification, inspection andcertification of repairs and alterations.


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8.0 EQUIPMENT ASSESSMENT, WORK SCOPE AND REPAIR ANDALTERATION PROCEDURES (STRATEGIES)

The ownermust ensure that competent persons are assigned to assess the

equipment, prepare and approve the work scope and repairor alteration procedures,and provide appropriate oversight over the repair oralteration. This includes, asapplicable, persons who have the required competence in: design,processconsiderations, corrosion, the code of construction, welding, inspection, NDE andtherelevant good engineering practices.

8.1 Root Cause that Prompted the Work

The owner must ensure that the root cause that prompted the repair or alteration isdetermined and then take suitable action to prevent similar causes that can affect the

integrity of the pressure equipment. This may require that the operational andmaintenance history of the itemis reviewed, other equipment in the system isinspected and that the inspection plans, process and mechanical design, andoperational and maintenance work processes are revisedaccordingly.

8.2 Condition of the Item to be Altered or Repaired

To assure the item will be safe for operation, the conditionof all components of theitem to be repaired or altered must be known before the work scope is established.An in-service inspection, non-destructive examinations or other tests, suitable toidentify the potential damage mechanisms, may then need to be done in order toverify the extent of the defect and to verify the condition of the item that is to berepaired or altered.AB-506 covers requirements for conducting in-serviceinspections.

8.3 Fitness-for-Purpose Evaluations

API579 covers fitness-for-service assessment methods and procedures forevaluating commonly encountered flaws, including general and widespread corrosionand pitting, blisters, crack-like flaws, and fire damage. Each API579 assessment ofthe flaws in a boiler or pressure vesselshall be submitted to an ABSA SCO for

acceptance, whenever theminimum design conditions of the original code ofconstruction are not met and it is intended that the item will be placed in servicewithout repairing it based on the results of the API 579 assessment.

The criteria for accepting pits and local thin areas in accordance with API510 andNBIC may generally be accepted without submission toABSA.Note: API577, Article 3.4, provides detailed information on flaw excavation.


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8.4 Preparation of the Work Scope

Information that may need to be defined in the work scope that the ownerprovides tothe repair organizationincludes, but is not limited to: base metal cleaning and other

preparation requirements such as degassing (bake out),welding requirements,material specifications and material testing requirements, heat treatment,NDE and reports that define the extentof damage, any pressure test or pressuretightness test requirements, coating requirements, the Inspector responsible forinspection (Alberta in-service inspector or ABSA SCO) and the Inspector s hold andinspection points.

8.5 Preparation of Repair and Alteration Procedures (Methods, Strategies)

The repair organization shall prepare a procedure and supporting documentation foreach item to be repaired or altered. This shall meet the owner s requirements (workscope), describe the step-by-step method to be used, and provide all the informationneeded to ensure the repaired or altered item is safe for operation at the approveddesign conditions. Theconstruction codes (refer to section 5 of this document), PCC-2, API510, API570, API577, NBIC and other applicable good engineeringstandards, provide detailed information that may need to be considered.

Applicable information that must be clearlydefined in the repair or alterationprocedure or supporting documents (design drawings, specifications, data reports,sketches, etc.) includes but is not limited to: weld joint designs and dimensions, weldsizes, the welding procedure specifications that are to be used for each specific weld

joint and any special welding considerations, material specifications and materialtesting requirements, NDE requirements, preheat requirements, postweld heattreatment (PWHT), any pressure testing requirements and any additional informationdesignated by the owner. (Section8.4 covers information that may need to beprovided by the owner). For alterations, additional design information and calculationsmay be required for procedure registration purposes per 8.6.

The Alberta repair and alteration report form,AB-40, is used to document thecompletion of a welded repair or alteration to a boiler or pressure vessel. This formdoes not need to be included in a package that is submitted to ABSA for registration.

However, for a simple boiler or pressure vessel repair, such as a basic repair to publicoccupancy equipment, the front of the AB-40 form, supplemented as required by adrawing or sketch showing the weld details and other required information, mayprovide enough detail to describe the repairor alteration procedure.

Some owners have developed standard procedures and strategies for typical repairs.These can provide excellent control methods for ensuring that all applicable factorsare taken into consideration when preparing the item-specific repair plan. However,


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the owner must still assign competent persons to approve each individual repairjobscope to ensure that the proposed procedure is appropriate and all the requiredinformation is available to ensure the mechanical integrity of the repaired item.

The repair or alteration procedure must be accepted by the Inspector prior to the startof work.

The repair organization must ensure that the repair procedures, supportingdocuments, welding procedures and other applicable quality system documents areavailable at the worksite and are understood by the persons who will be executing thework.

8.6 Submission of Repair and Alterationprocedures and design information to ABSA

PESR section 40 establishesthat the owner must ensure that the design informationfor an alteration of pressure equipmentissubmitted to ABSA (Design Survey) forregistration in accordance with PESR section 14. The allowable stresses of theoriginal code of construction shall be used for all alterations, including re-rating. PESRsection 40 also establishes that the owner may be required to submit to ABSA detailsof the repair procedures for acceptance.

8.6.1 Alteration procedures forBoilers and Pressure Vessels

All alterations to ASME Section VIII Division 2 and 3 vessels require submission toABSA design survey for review and registration. This requirement applies to the

pressure boundary and anything attached to the pressure boundary.

All other alterations to boilers and pressure vessels must be submitted to ABSAsdesign survey department for review and registration of the alteration design exceptthat the following design changesdo not require submissiontoABSA design surveyfor review and registration:

The addition of nozzles identical to existing nozzles, or for which reinforcementcalculations are not required,which meetthe other applicable parts of the originalcode of construction (example UG-45) and are located not less than 3 times the

sum of their corroded inside diameters from existing nozzles.

The addition of non-load bearing attachments to pressure-retaining items whenpostweld heat treatment is not required.

Alterations that meet the registration exemption criteria above shall bedocumented as repairs and must be approved by the owner-user s engineer orInspector when they are inspected and certified by the owner per section6, or


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by the ABSA Inspector when the item is not inspected and certified by theowner-user.

PESR section 15 lists the information, as applicable, that must be provided to ABSA

Design Survey in order to register an alteration to a boiler or pressure vessel. ABSAform AB-31 Design Registration Application must be provided with the alterationsubmission.

8.6.2 Repair Procedures for Boilers and Pressure Vessels

All repair procedures for Division 2 and 3 vessels, and any other repair procedure thatthe ABSA Inspector considers needs formal assessment, shall be submitted to ABSADesign Survey for acceptance prior to the start of work. This is provided for in PESRsection 40(5).

8.6.3 Repair and Alteration Procedures for Pressure Piping

Piping and components that are replaced, modified or added to an existing pipingsystem in conformance to the original registered piping designspecifications are notconsidered to be alterations and the design information does not require submissionto ABSA Design Survey for review and registration. Any such replacements,modifications and additions must be approved by the owner-user s engineer.Other piping systems must be constructed in accordance with the latest adoptedconstruction Code, and the design must be submitted to ABSA in accordance withPESR section 14 and section 16 when the aggregated capacity of the new system

exceeds 500 liters. ABSA forms AB-31 Design Registration Application and AB-96Engineering Requirements for Design and Construction of Pressure Piping Systemsmust be submitted with the piping registration submission.9. 0 QUALIFICATIONS OF INSPECTORS

The Inspector s employer (ABSA, Owner-user, Inspection Company) must maintainsuitable documentation that defines the experience, training and qualificationsrequired for each person involved in repair inspection activities. This shall includeappropriate training in: legislation, AB-513, the applicable codes of construction and

recognized good engineering standards, welding, NDE and other relevant activities.

The Inspector s employer shall maintain suitable verification records to document thatthe above requirements have been met and that the person is competent to performthe inspection and certification activity.

Inspectors who inspect and certify repairs to boilers and pressure vessels under theiremployer s CAP must hold an Alberta in-service inspector certification.


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API577 recommended practice provides guidance to inspectors on weldinginspection as encountered with fabrication and repair of refinery and chemical plantequipment and piping, and provides valuable information to supplement therequirements covered in the new construction codes and the referenced post

construction codes.

10.0 WELDING

10.1 Welding and Brazing Procedures

All welding, brazing and other joining procedures used for repairs and alterations shallmeet the registration and other requirementsper PESR section 18 and 27.Supplementary welding procedure requirements and welding data shall also bedeveloped, as required toensure the integrity of the welded item under the operatingconditions.

Some additional welding considerations and welding procedure requirements areidentified in publications such as API510, NBIC, API577 and API582.

10.2 Welders

Welders and welding operators must meet the requirements of the Pressure WeldersRegulation and have the required valid Alberta performance qualification cards for thewelding procedures to be used. Additional testing and assessment shall be done bythe repair organization as required to ensure that the welder has the required skill for

the welding that is to be done. Some repairs may require specific weld sequences,techniques andadditional welder tests.

11.0 EXAMINATION, INSPECTION AND CERTIFICATION OF REPAIRSAND ALTERATIONSOF BOILERS AND PRESSURE VESSELS

The proposed repair or alteration methods for pressure equipment shallbe accepted,prior to start of work, by the Inspector who is responsible for inspecting and certifyingthe repair or alteration. Alteration procedures (and repair procedures when requiredby an ABSA Inspector) shall have been accepted by ABSA s Design Survey

Department.

11.1 Inspection and Test Plan (ITP)

The organization performing the repair or alteration work must prepare an inspectionand test plan (travel sheet) for each item that is to be repaired or altered. This shall listin sequence all the examinations, inspections and tests needed to ensure that all therepair and alteration procedure elements are completed and work meets theAB-513


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requirements. The repair organization must ensure that sufficient competentresources are assigned to complete all the specified examinations.

The ITP shall include provision to enable the Inspector to designate his or her

inspection and hold points for the activities he or she needs to witness, and todocument acceptance of the repair or alteration procedure prior to the start of work.

11.2 Inspection and Certification

All repairs and alterations to boilers and pressure vessels must be inspected andcertified by an Inspector.

The owner-user Inspector is responsible for inspecting and certifying:

a. repairs under an owner-user Certificate of Authorization Permit as

provided for in Section 6.2 of this document.

The ABSA Inspector is responsible for inspecting and certifying:

a. all alterations;b. all repairs and alterations to equipment in facilities of public occupancy,c. all repairs and alterations to ASME Section VIII, Div. 2 & 3 vessels.d. repairs and alterations that are done at a repair organizations (i.e. not

an owner-user s) facility,e. all repairs and alterations done at owners sites that are not inspected

and certified by the owner-user under its Certificate of Authorization

Permit.

The ABSA Inspector may authorize an inspection companyInspector or an owner-user Inspectorto inspect and certify a specific repair to a boiler or pressure vesselthat is not covered under the scope of an owner-user s CAP, providing the inspectioncompany or owner-user has a CAP that covers the inspection and certification ofrepairs and the ABSA Inspectoris satisfied that the item will berepaired inaccordance with AB-513.

11.3 Inspection and Certification Activities

Inspectors who inspect and certify repairs and alterations must complete all theinspections needed to ensure that the item is restored to a condition that is suitablefor safe operation at the design conditions. This would include the applicableinspections that are identified in the code of construction used.


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Typical inspection activities for an ASME Section VIII Div 1 pressure vessel repairinclude:

- verifying that the repair and alteration organization has a valid ABSA-

issued Certificate of Authorization Permit(CAP) for the scope of work;- monitoring the repair and alteration organization s quality system;- reviewing the repair or alteration procedure (plan) and related drawings

specifications, and other information to confirm that it is suitable for thescope of work, and documenting acceptance of this review;

- ensuring the repair organization has prepared a suitable inspection andtest plan (checklist/travel sheet) that lists all the steps, examinations,inspections, and tests needed for the work scope and is used inaccordance with the repair organization s quality system manual;

- documenting completion of each required inspection by initial and dateon the repair organization s inspection and test plan (travel sheet), at thetime of the inspection;

- verifying welding procedure requirements and monitoring that they arefollowed;

- ensuring welders are qualified, for the procedure used, under thePressure Welders Regulation;

- ensuring the correct material is used for the work;- performing visual examinations;- verifying that the required nondestructive examinations have been done

and properly documented;- verifying that required heat treatment has been done and properly

documented;- verifying that any pressure tests and alternative examination and tests

have been done, per the accepted repair or alteration procedure, andwitnessing any pressure tests;

- verifying and certifying the AB-40, Repair and Alteration Report.

Owner-users who have demonstrated that they have an appropriate organization,documented work processes and designated competent resources to manage therepairs and alterations per section6 may authorize a competent person who does nothold an in-service inspector certificate to assist the Inspector by performing

designated inspections during the execution of the work. TheInspector must bedirectly involved in the inspection activities, be available at the worksiteand:

- approve the repair procedure, execution methods, materials weldingprocedures and testing prior to the start of work.

- confirm that the person designated to perform the in-processinspection has the required documented competence.

- review the completed repair documentation. This shall include the


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repair procedure, the ITP (travel sheet), the AB-40 and any otherrelevant documents.

- certify the Certificate of Inspection section of the AB-40.

11.4 Boilers and Pressure Vessels Repairand Alteration Report, AB-40

ABSA Form AB-40, Boilers and Pressure Vessels Repair and Alteration Report, shallbe used to document and certify each alteration and each repair. AB-40a is a guidefor completingthe AB-40. These forms are available on ABSA s website atwww.absa.ca.

The repair organization is responsible to ensure an AB-40 is submitted to ABSA, forevery repair or alteration of boilers and pressure vessels performed in Alberta, within10 days of the completion of the repair or alteration. This report must also be providedto the owner.

When the item is to be installed in Alberta, but the repair or alteration has beencompleted outside of Alberta, the appropriate Canadian provincial form, or NationalBoard R1 Report of Repair or R2 Report of Alterations, must be submitted to ABSA.

The owner must retain the AB-40 on file forthe life of the equipment.

PESR Section 1(1)(k) lists some of the records that must be maintained by the owner,PESR Section 41 establishes that records must be maintained and Section 36establishes requirements for notification and provision of equipment records when

there is a change of ownership.

11.5 Repair or Alteration Nameplate

An alteration nameplate shall be attached adjacent to the original boiler or pressurevessel manufacturer s stamping whenever the alteration procedure is required tobesubmitted to ABSA design survey. A sample of the nameplate is shown on the nextpage.

Repair nameplates are generally not required for items that are installed in Alberta as

this repair history is available through equipment records and the repairand alterationreports that ABSA keeps on file. Owners are also required to maintain current recordsfor all repairs or alterations of their equipment.

Repair nameplates are required for repairs to pressurized cargo transport vessels,and if required by the NBIC for R stamped repairs. Repair nameplates may also berequired by the owner or the repair organization, or when the ABSA Inspectorconsiders this necessary (e.g., for out-of-province equipment, and when there hasbeen extensive repair work done).
http://www.absa.ca/


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Sample Nameplate for Repairs and Alterations

(The following information must be shown when a nameplate is required.)

by

(Identify Repaired ,Altered, or Rerated as

applicable)

(Show Name ofOrganizationdoing work)

MAWP atTEMP.

MDMT at pressure

CRNIndicateUnits

Date work completed.

NOTE: Markings shall be produced by casting, etching, embossing,debossing, stamping or engraving.Letters and numbers must be at

least 5/32" high. Whole numbers shall be used on the nameplate.

When an alteration includes a change to the MAWP, design temperature or MDMT,the new values shall be marked on the alteration nameplate and the values that arechanged on the original nameplate shall be marked out (i.e., a single horizontal lineshall be stamped through the changed value).The following excerpt of markingsprovides an example of this requirement:

Original nameplate stamping Rerate nameplate stamping

MAWP 1440 PSI at 100 Deg. F MAWP 1200 PSI at 100 Deg. F

Attachment of the alteration nameplate shall be witnessed by the ABSA Safety CodesOfficer.


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12.0 EXAMINATION, INSPECTION AND CERTIFICATION OF REPAIRSAND ALTERATIONS TO PIPING AND FITTINGS

The requirements covered in the general section, and the principles in Section 11,examination and inspection of boilers and pressure vessels, also apply for pressurepiping and fittings.

Note: Pressure piping listed under PESR section 4, partial exemptions, is exemptfrom the specific requirements defined in this AB-513 document. However, the owneris responsible to ensure that any repairs done to such piping conform to the originalCode of Construction.

Repairs and alterations of piping systems and fittings shall be designed, inspected,documented and certified as provided for in the repair oralteration organization squality system manual filed with ABSA.

The owner must define the competence requirements for theirInspectors who inspectand certify repairs and alterations to pressure pipingin accordance with Section 9. AnAlberta in-service inspector certificate of competency is not required, unless the pipingis classed as boiler external piping.

The Pressure Piping Construction and Test Data Report, AB-83, is used to documentrepairs and alterations to piping systems. If the AB-83 sections do not cover the scopeof the piping repair, for example welded repairs for cracks, pits etc, a supplement

should be added to the AB-83 and suitable notation made in the remarks section.

Pressure piping data reports must be retained on file by the owner for at least fiveyears(refer PESR section 31).

13.0 HOT TAPPING

Hot tapping is the technique of attaching a welded branch fitting or a bolted ormechanical fitting to piping or equipment that is in service and then creating anopening in that piping or equipment by drilling or cutting a portion of the item within

the attached fitting. API2201 publication provides an in-depth review of the safetyaspects that need to be considered when hot tapping.

Hot tapping is deemed to be an alteration. All requirements of AB-513 for alterationsapplicable to the item of pressure equipment that is to be hot tapped must be met inaddition to the requirements specified in this section.API2201 is a recognized goodengineering practice that shall also be followed when developing hot tappingprocedures and for executing all hot tapping activities.


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Note: API577 Section 11 provides additional information of welding issues related tohot tapping and in-service welding.

Hot tapping of pressure piping systems and pressure vessels may be permitted. Hot

tapping of boilers is not permitted.

General requirements for hot tapping that are contained in the AlbertaOccupationalHealth and Safety Regulationapply to all hot tapping activities, including hot tappingthat is exempt from the Safety Codes Act.Persons involved in hot tapping activitiesare responsible for compliance with all applicable legislation.

Hot tapping may be necessary when it is not feasible, or it is impractical, to take thepressure equipment out of service for making repairs or for installing additionalconnections. The process of hot tapping can be very hazardous. Hot taps can beaccomplished safely provided that there are effective procedures in place to control allhot tap activities. Precautions include:

1. The owner shall maintain documented procedures that cover the controls for allhot tap activities including:- all the relevant information in AB-513 and API2201;- ensuring that competent persons and required resources are assigned for all

hot tap activities;- conducting job analysis and preparing the justification that no alternative

method is feasible;- conducting a hazard evaluation and developing a risk reduction plan;

- preparing instructions for managing the changes (MOC) safely;- developing the design of the hot tap connection;- preparing the job-specific hot tap procedures;- establishing welding and mechanical attachment requirements.

2. Hot tap is deemed to be an alteration and the hot tap procedure must besubmitted to ABSA for each proposed hot tap. Notwithstanding this requirement,owner-users, who have an acceptable hot tap procedure and an appropriateorganization, documented work processes and designated competent resourcesto manage hot taps under their CAP, may be authorized to perform hot taps

without submitting individual hot tap procedures for registration.

3. Hot taps to pressure vessels shall be inspected by ABSA.

4. A Contractor/Owner installing a fitting by welding for attaching a valve andmachine for hot tapping shall:- hold a valid Certificate of Authorization Permit for the hot tap activity, per

AB-513 Section6;


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- install the fitting in accordance with the requirements of the engineering design,hot tap procedure and the QMS;

- certify the installation using an AB-83 form if the installation was done on apressure piping system, or an AB-40 form if the installation was done on a

pressure vessel.

5. The company that uses the hot tap equipment shall have an AlbertaCertificate ofAuthorization Permit for this activity and perform the work in accordance with itsown and the owner s hot tap procedures.


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REVISION LOG

Rev # Date DescriptionEdition 2, Rev 0 2011-06-21 New edition issuedEditorialRevisions

2011-10-19 Editorial revisions as indicated by the vertical line inthe left margin

AB-513 Repair and Alteration Requirements

Documents

Transcript of AB-513 Repair and Alteration Requirements