REPAIR

PETRONAS Management Training Sdn Bhd 2006. All right reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.

Repair

Observe the following rules

Definition work necessary to restore vessel to a condition suitable for safe operation at design condition
Use only repair procedure which has been qualified by pressure vessel engineer

Employ only qualified welding procedures & welders to do the job

No welding if carbon content exceeds 0.35%

PMTSB 2006

Repair

Common repair types 1. Crack repair 2. Patch repair using fillet welds 3. Full encirclement lap band repair

PMTSB 2006

Repair

Common repair types 1. Crack repair 2. Patch repair using fillet welds 3. Full encirclement lap band repair

PMTSB 2006

Repair

Crack repair Important!!! Consult your pressure vessel engineer before repairing any crack General steps: 1. Remove crack

2. Build up area by welding

3. Ensure repaired area is free from defect 4. Perform PWHT, if required

5. Perform pressure test if required

PMTSB 2006

Repair

Crack repair Step 1 Remove crack Remove completely by making U or V shaped groove Perform NDE to ensure area is free from defect

PMTSB 2006

Repair

Crack repair Step 2 Build up area by welding Ensure filler metal is as strong as base metal Preheat base metal temperature to a minimum of 150oC Preheat area should cover 4 of material or 4 times thickness, whichever is greater, on both sides of weld Ensure interpass temperature is maintained between layers If required, ensure post heat is immediately applied after welding

PMTSB 2006

Repair

Crack repair Step 3 Ensure repaired area is free from defect Perform NDE on repaired area either PT or MT, as required For vessels made of P-3, P-4, or P-5 materials, which are operated in hydrogen service, they should be inspected for delayed cracking using ultrasonic examination after 24 hours

PMTSB 2006

Repair

Crack repair Step 4 Perform PWHT, if required Normally required for thick ferrous vessels over 1 Normally required for vessels made of P-4, or P-5 materials, regardless of thickness

PWHT area should cover at least 2 times thickness on both sides of welded area
PWHT should be monitored by at least 2 thermocouples

PMTSB 2006

Repair

Crack repair Step 5 Perform pressure test, if required Where possible, use water and pressurize to 130% of MAWP After holding for a certain amount of time, reduce pressure to 90% of test pressure and perform close visual inspection If pressure test using water is not possible, pneumatic test at 110% MAWP is possible

Similarly, after holding for a certain amount of time, reduce pressure to 90% of test pressure and perform close visual inspection
PMTSB 2006

Repair

Common repair types 1. Crack repair 2. Patch repair using fillet welds 3. Full encirclement lap band repair

PMTSB 2006

Repair Patch repair using fillet welds Usually for temporary repairs of thinning area Important!!! Consult your pressure vessel engineer before attempting this method The engineer must ensure by calculations that;

Fillet patches provide design safety equivalent to reinforced openings

They effectively absorb all membrane stress in shell They dont create local stress at the fillets that exceed allowable stresses Steps shall be performed in the same sequence as crack repair Fillet patches shall have rounded corners PMTSB 2006

Repair

Common repair types 1. Crack repair 2. Patch repair using fillet welds 3. Full encirclement lap band repair

PMTSB 2006

Repair

Full encirclement lap band repair Important!!! Consult your pressure vessel engineer before attempting this method Can be considered long term repair if; Not used for crack repair on pressure vessel

Can take full design pressure

Use full penetration butt welds Fillet welds can carry full longitudinal load, using joint efficiency of 0.45 Not subject to fatigue

PMTSB 2006

End of REPAIR

PETRONAS Management Training Sdn Bhd 2006. All right reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.