8 Repairs, Alterations, and Rerating of Piping Systems

Question 1

8. 1 Repairs and Alterations
9. 1.1 General

The principles of ________ to which the piping system was built shall be followed to the extent practical for in-service repairs

Answer 1

ASME B31.3 or the code

Question 2

8. 1 Repairs and Alterations
9. 1.1 General

When ASME B31.3 cannot be followed because of its new construction coverage (such as revised or new material specifications, inspection requirements, certain heat treatments, and pressure tests), the piping engineer or inspector shall be guided by _____ in lieu of strict conformity to ASME B31.3.

Answer 2

API 570

Question 3

8. 1 Repairs and Alterations
9. 1.2 Authorization

All repair and alteration work shall be done by a repair organization as defined in Section 3 and shall be authorized by the _______ prior to its commencement

Answer 3

inspector

Question 4

8. 1 Repairs and Alterations
9. 1.2 Authorization

Authorization for alteration work to a piping system may not be given without prior consultation with, and approval by, the _________

Answer 4

piping engineer

Question 5

8. 1 Repairs and Alterations
9. 1.3 Approval

All proposed methods of design, execution, materials, welding procedures, examination, and testing shall be approved by the _____ or by the ______, as appropriate

Answer 5

piping engineer

Question 6

8. 1 Repairs and Alterations
9. 1.3 Approval

_________ approval of on-stream welding is required.

Answer 6

Owner/user

Question 7

8. 1 Repairs and Alterations
9. 1.3 Approval

Welding repairs of cracks that occurred in-service should not be attempted without prior consultation with the __________ in order to identify and correct the cause of the cracking

Answer 7

piping engineer

Question 8

8. 1 Repairs and Alterations
9. 1.3 Approval

The _________ shall approve all repair and alteration work at designated hold points and after the repairs and alterations have been satisfactorily completed in accordance with the requirements of API 570.

Answer 8

inspector

Question 9

8. 1 Repairs and Alterations
9. 1.4 Welding Repairs (Including On-stream)
10. 1.4.1 Temporary Repairs

_________ shall not be repaired in this manner unless the piping engineer has determined that cracks would not be expected to propagate from under the sleeve.

Answer 9

Longitudinal cracks

Question 10

8. 1 Repairs and Alterations
9. 1.4 Welding Repairs (Including On-stream)
10. 1.4.1 Temporary Repairs

The design of temporary enclosures and repairs shall be approved by the ____________

Answer 10

piping engineer.

Question 11

8. 1 Repairs and Alterations
9. 1.4 Welding Repairs (Including On-stream)
10. 1.4.1 Temporary Repairs

If the repair area is localized (for example, pitting or pinholes) and the SMYS of the pipe is not more than _____________, and a Fitness-for-Service analysis shows it is acceptable, a temporary repair may be made by fillet welding a properly designed split coupling or plate patch over the pitted or locally thinned area (see 8.1.4 for design considerations and Annex C for an example)

Answer 11

40,000 psi (275,800 kPa)

Question 12

8. 1.4 Welding Repairs (Including On-stream)
9. 1.4.1 Temporary Repairs

When installing a fillet-welded patch adjacent to an existing fillet-welded patch, the minimum distance between the toe of the fillet weld shall not be less than:
(3)

Answer 12

d = 4 Rt

Question 13

8. 1.4 Welding Repairs (Including On-stream)
9. 1.4.1 Temporary Repairs

Any leak in a Class 1 service or where a risk ranking is determined to be high, shall be first reviewed by a __________ determine if the work can be safely performed while the system remains on stream.

Answer 13

piping engineer

Question 14

8. 1.4 Welding Repairs (Including On-stream)
9. 1.4.1 Temporary Repairs

Temporary repairs should be removed and replaced with a suitable permanent repair at the ___________

Answer 14

next available maintenance opportunity

Question 15

8. 1.4 Welding Repairs (Including On-stream)
9. 1.4.2 Permanent Repairs

Repairs to defects found in piping components may be made by preparing a ___________ that completely removes the defect and then filling the groove with weld metal deposited in accordance with 8.2.

Answer 15

welding groove

Question 16

8. 1.4 Welding Repairs (Including On-stream)
9. 1.4.2 Permanent Repairs

Insert patches (flush patches) may be used to repair damaged or corroded areas if the following requirements are met:

a) __________ groove welds are provided;
b) for _________ piping systems, the welds shall be 100 % radiographed or ultrasonically tested using NDE procedures that are approved by the inspector;
c) patches may be any shape but shall have ________corners [1 in. (25 mm) minimum radius].

Answer 16

a) full-penetration
b) Class 1 and Class 2
c) rounded

Question 17

8. 1.4 Welding Repairs (Including On-stream)
9. 1.5 Nonwelding Repairs (On-stream)

The design shall include control of ________ if the piping component being enclosed is (or may become) insufficient to control pressure thrust

Answer 17

axial thrust loads

Question 18

8. 1.4 Welding Repairs (Including On-stream)
9. 1.5 Nonwelding Repairs (On-stream)

During ______________, temporary leak sealing and leak dissipating devices, (e.g., wire wrapping, mechanical clamps, etc) including temporary repairs on valves, shall be removed and appropriate actions taken to restore the original integrity of the piping system.

Answer 18

turnarounds or other appropriate opportunities

Question 19

8. 1.4 Welding Repairs (Including On-stream)
9. 1.5 Nonwelding Repairs (On-stream)

Temporary leak sealing and leak dissipating devices may remain in place for a longer period of time only if approved and documented by the __________

Answer 19

piping engineer

Question 20

8. 1.4 Welding Repairs (Including On-stream)
9. 1.5 Nonwelding Repairs (On-stream)

Procedures that include leak sealing fluids (“pumping”) for process piping should be reviewed for acceptance by ___________

Answer 20

the inspector or piping engineer.

Question 21

8. 2 Welding and Hot Tapping
9. 2.1 General

All repair and alteration welding shall be done in accordance with the principles of __________________________

Answer 21

ASME B31.3 or the code to which the piping system was built.

Question 22

8. 2 Welding and Hot Tapping
9. 2.1 General

Any welding conducted on piping components in operation shall be done in accordance with _______

Answer 22

API 2201

Question 23

8. 2 Welding and Hot Tapping
9. 2.2 Procedures, Qualifications, and Records

The repair organization shall use welders and welding procedures qualified in accordance with _________________

Answer 23

ASME B31.3 or the code to which the piping was built

Question 24

8. 2 Welding and Hot Tapping
9. 2.2 Procedures, Qualifications, and Records

The repair organization shall maintain records of welding procedures and welder performance qualifications. These records shall be available to the inspector _____ to the start of welding.

Answer 24

prior

Question 25

8. 2 Welding and Hot Tapping 8. 2.2 Procedures, Qualifications, and Records The repair organization shall maintain records of welding procedures and welder performance qualifications. These records shall be available to the _______ prior to the start of welding.

Answer 25

inspector

Question 26

8. 2 Welding and Hot Tapping 8. 2.3 Preheating and PWHT 8. 2.3.2 Preheating Preheat temperatures used in making welding repairs shall be in accordance with the ____________

Answer 26

applicable code and qualified welding procedure.

Question 27

8. 2 Welding and Hot Tapping 8. 2.3 Preheating and PWHT 8. 2.3.3 PWHT See 8.2.4 for an alternative preheat procedure for some PWHT requirements. Exceptions for temporary repairs shall be approved by the ________ and be in accordance with ASME PCC-2, Article 2.9.

Answer 27

piping engineer

Question 28

8. 2 Welding and Hot Tapping 8. 2.3 Preheating and PWHT 8. 2.3.3 PWHT Local PWHT may be substituted for 360° banding on local repairs on all materials, provided the following precautions and requirements are applied. a) The application is reviewed, and a procedure is developed by the _________ b) In evaluating the suitability of a procedure, consideration shall be given to applicable factors, such as base metal thickness, thermal gradients, material properties, changes resulting from PWHT, the need for full-penetration welds, and surface and volumetric examinations after PWHT. c) A preheat of ________, or higher as specified by specific welding procedures, is maintained while welding. d) The required PWHT temperature shall be maintained for a distance of not less than _________ the base metal thickness measured from the weld. The PWHT temperature shall be monitored by a suitable number of thermocouples (a minimum of two) based on the size and shape of the area being heat treated. e) Controlled heat also shall be applied to any branch connection or other attachment within the PWHT area. f) The PWHT is performed for code compliance and not for _____________

Answer 28

a) piping engineer. c) 300 °F (150 °C) d) two times e) Controlled heat also shall be applied to any branch connection or other attachment within the PWHT area. f) environmental cracking resistance.

Question 29

8. 2 Welding and Hot Tapping 8. 2.4 Preheat or Controlled Deposition Welding Methods as Alternatives to Postweld Heat Treatment However, prior to using alternative methods, a ____________ shall assure the alternative is suitable based on a metallurgical review.

Answer 29

piping engineer