ASME Temporary Repairs 101410-1

8/6/2019 ASME Temporary Repairs 101410-1

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Temporary Repairs

Presented by: Charlie RutanFormally Senior Engineering Advisor for LyondellBasell

Fixed Equipment Inspection, Repair, and Failure Analysis

Houston, Texas

October 14, 2010


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Special Acknowledgements

Michael Guillot, Ph.D., P.E. Stress Engineering

Services, Inc.; [email protected] ASME Fixed Equipment Inspection, Repair, andFailure Analysis SeminarHouston, Texas

August 1820, 2009
mailto:[email protected]:[email protected]


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Contents of Presentation

Repairs made at every plant to keep things

running, but considered as temporary repairs byAPI or other governing bodies

On-line, non-welded repairs

On-line, welded repairs Documentation and tracking of temporaryrepairs


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Temporary Repairs Definitions

From API 510 3.60: Repairs made to pressure vessels to restore sufficientintegrity to continue safe operation until permanent

repairs can be conducted

From API 570 3.45: Repairs made to piping systems to restore sufficientintegrity to continue safe operation until permanent

repairs can be scheduled and accomplished within atime period acceptable to the Inspector or PipingEngineer


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Temporary Repairs Definitions

(Continued) On-line, non-welded repairs

Flange repair Enclosures


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Flange Repair

Wire-wrap procedure

Used in flange gaps up to10 mm (0.4 inches)

Pressure limitations

Immediate off-the-truck

repair

Excessive peening mustbe avoided to preventbolts from being

overloaded


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Mechanical Clamp Repair (continued)

Hot Tapping can be performed throughmechanical clamps. This is a very effective wayof preventing a crack to propagate.


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Hot Tap

Hot Tapping

Line Stops


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Physical limitations (continued) Metal Thickness > 0.75 Difficulties excessivemetal shavings

Required thickness calculations, body bound bolts, and nopilot drill

Hot Tapping in the horizontal direction Turn thevalve up side down and let the shavings fall into thevalve bonnet

Local stress relieving may be required for carbonsteels due to the steels thickness This may be areal issue! (Cooper Heat)


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On-Line Weld Repairs (continued)

In some cases these repairs can be consideredpermanent repairs. Allow clamp to come to line temperature

Use the proper welding procedure First weld will be a circumferential weld at one end ofthe clamp Second welds are the longitudinal welds After welds have cooled the circumferential weld canbe made.


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On-Line Weld Repairs Welding Procedures (continued)

Process conditions are key and will define the welding criteria

TIG welding is preferred for the first 3 or 4 passes.

A 3/32 diameter weld rod should be used for the next 3 to 4passes

Typically then a 1/8 diameter rod can then be usedNote: on the inside of a 6 pipe with a wall thickness of 0.280 the

wall temperature was measured to be 740oF with the TIG heatarea of .39 in2 while the 3/32 diameter weld rod had the sametemperature but the area was increased 1.83 times from 0.39 in2

to 0.95 in2


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History of Hot Tapping

The first hot taps were made withsledgehammers and pointed bars

H. Muller, founder of Muller Company, patentedfirst tapping machine (1872)

Frank Wheatley Company of Tulsa Oklahomadeveloped first tapping machine for oil and gasindustry

In 1932, J. E. Polston and A. M. Hill inventedP&H Tapping Machine. A telescoping boring barwas the special design feature.


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Very Early Hot Tap


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Tapping Through A Pipe Wall


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Pipe ID Flow Stop


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Modified Muller Hot Tap


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Modified Muller Line Stop


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Hot Tap vs. Clamp for Repair


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Hot Tap for Repairs


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Lap patch in a refinery FCCU In FCCU units, catalyst continually circulates attemperatures of 1200 to 1400F (650 to 750C). Catalyst is

circulating at high velocity, so it is extremely erosive.

Carbon steel is used in services < 750F (400C). At highertemperatures, it loses mechanical strength, and therefore itsability to withstand pressure.


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Documentation & Tracking of Temporary Repairs

API 510 8.1.5.1 Temporary Repairs

8.1.5.1.1 General

Temporary repairs should be removed and replaced with suitable permanentrepairs at next available maintenance opportunity.

Temporary repairs may remain in place for a longer period of time only ifevaluated, approved, and documented by engineer and inspector.

Documentation of temporary repairs should include

Location of temporary repairSpecific details, e.g., material of construction, thickness, size of welds, NDE

performed

Details of analyses performedRequirements for future inspections

Due date for installing permanent repair

Inspection plans shall include monitoring integrity of temporary repairuntil permanent repairs are complete


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API 510 8.1.5.1 Temporary Repairs (contd.) 8.1.5.1.2 Fillet-Welded PatchesFillet-welded patches may be used to make temporary repairs to

damaged, corroded, or eroded areas of pressure vessel components.

Cracks shall not be repaired in this manner unless the engineerdetermines that cracks will not be expected to propagate from underthe patch. In some cases, the engineer may need to perform afitness-for-service analysis.

Temporary repairs using fillet-welded patches shall be approved byan inspector and engineer. Use of fillet-welded patches may be

subject to acceptance of governing jurisdiction.


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API 570 7.6 Reporting and Records for Piping SystemInspection

Any significant increase in corrosion rates shall be reported toowner/user for appropriate action (Change in process conditions)

Owner/user shall maintain appropriate permanent and progressiverecords of each piping system covered by API 570.

These records shall contain pertinent data such a

Piping system service

ClassificationIdentification numbersInspection intervalsDocuments necessary to record name of individual performing testing, date,

types of testing, results of thickness measurements and other tests,inspections, repairs (temporary and permanent), alterations, or rerating.


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D t ti & T ki f T R i


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API 570 8.1.3 Welding Repairs (including on-stream)

8.1.3.1 Temporary Repairs (contd.)For minor leaks, properly designed enclosures may be welded overthe leak while piping system is in service, provided inspector issatisfied that adequate thickness remains near weld, and pipingcomponent can withstand welding without likelihood of furthermaterial damage, such as from caustic service.

Temporary repairs should be removed and replaced with a suitable

permanent repair at next available maintenance opportunity.Temporary repairs may remain in place for a longer time only ifapproved and documented by piping engineer.



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Temporary repairs should be removed and

replaced with a suitable permanent repair at thenext available maintenance opportunity.


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ASME Temporary Repairs 101410-1

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